System and apparatus for an automated container filling production line

ABSTRACT

An automated container production line for automatically removing, orienting, filling, sealing and providing a label and applying a straw to the outside of the labeled container is provided which utilizes a novel orienting conveyor for receiving unoriented containers from a supply bin and orienting the containers for a plurality of novel short production lines having a positioning screw conveyor which intermittently starts and stops the advancement of the containers as groups of containers in which various groups of containers are simultaneously filled, sealed, inspected and then subsequently transported to a sleeving device for adding labels, a heat shrink tunnel for fastening the sleeve to the container and then to a novel straw applicator for subsequently attaching a straw to the outside of the container. The novel automated container filling, sealing and inspecting production line includes a computer program for controlling the production line in conjunction with various sensor devices for determining whether the containers are properly aligned, properly filled, properly sealed and completed in accordance with the highest quality control standards to not only assure product quality but also assure that containers not meeting specifications are removed from the production line and not processed further.

[0001] This application is a divisional of U.S. patent application Ser.No. 10/359,138, filed Feb. 6, 2003, which is a divisional of U.S. patentapplication Ser. No. 09/659,618, filed Sep. 11, 2000, now U.S. Pat. No.6,523,328, which claims the benefit of U.S. Provisional Application Ser.No. 60/153,244, filed Sep. 13, 1999.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The invention pertains to a method and apparatus for an automatedcontainer filling production line, which at one end has a supply ofunoriented containers and at the other end provides a filled, sealed andconsumer packaged end product. In the preferred application of theinvention the filled, sealed and consumer packaged end product includesa wrapped telescoping straw attached to the outside of the containerpackaged for final consumer use.

[0004] More specifically, the invention relates to an automatedcontainer filling production line having continuous and discontinuousoperating systems integrated together to form a seamless production linecontrolled by a computer and related software to automatically takeunfilled, unoriented containers, orient those containers, fill, seal,inspect and remove unsatisfactory containers from the novel filling andsealing machine and then automatically transport properly filled andsealed containers to a sleever to automatically label the container,heat-shrink the sleeve to the container and optionally apply apre-packaged straw to the outside of the container in the novelautomated integrated container filling production line.

[0005] The novel method and system for the integrated automatedcontainer filling production line includes, in the preferredapplication, an infeed conveyor which includes a novel orientationconveyor to transport randomly oriented containers from a supply hopperand orient and provide a rough sequencing of those containers into aplurality of individual production lines that are introduced into anovel filling and sealing machine having a plurality of productionlines. The novel orientation conveyor removes the randomly orientedcontainers from the supply bin and then orients and roughly sequencesthe containers into the plurality of production lines by utilizing thepliant orientation plates that imitate the action of the human hand insequencing and orienting the containers in a ‘bottom up’ ‘top down’orientation and then transports the ‘bottom up’ ‘top down’ containers toa turning plate and drop-chute which turns the ‘bottom up’ ‘top down’container to a ‘top up’ ‘bottom down’ configuration in a plurality ofproduction lines before transporting the oriented and roughly sequencedcontainers to the novel filling and sealing machine in the novelproduction line of the invention.

[0006] In an alternative application of the invention the integratedautomated container filling production line includes an embodiment ofthe novel orientation conveyor which orients randomly orientedcontainers in a ‘top up’ ‘bottom down’ orientation and then roughlysequences the containers in a plurality of production lines by utilizingpliant orientation plates and pivotable rods that simulate the action ofthe human hand to orient and roughly sequence the containers in aplurality of production lines. The ‘bottom down’ ‘top up’ containers aretransported in the orientation conveyor to a plurality of drop guideplates disposed in each of the plurality of production lines to assistin dropping the containers in a ‘top up’ ‘bottom down’ orientation in aplurality of drop chutes. The ‘top up’ ‘bottom down’ oriented androughly sequenced containers are then deposited on an infeed conveyorthat introduces the oriented and rough sequenced containers to apositive positioning screw conveyor having a plurality of productionlines in a novel filling and sealing machine.

[0007] The novel filling and sealing machine of the novel productionline of the invention receives a plurality of ‘top up’ ‘bottom down’flat-bottomed containers from a conveyor that provides a roughsequencing of containers and introduces those containers to a positivepositioning screw control conveyor system in a plurality of productionlines in which positive conveyor control forces are maintained on thebottom and sides of the container in a screw conveyor that provides adiscontinuous travel of the container to a plurality of filling andsealing stations in the novel filling machine. In one operational modeof the invention a plurality of screw conveyors receive a firstplurality of oriented and roughly sequenced containers which are thenpositively engaged around the sides and bottom and then conveyed to thefilling portion of the machine. At this point both the screw conveyor isstopped and the advancement of the containers is stopped by the positivecontrolled conveyor means at which time the first plurality ofcontainers are filled with a filler mechanism providing for the positivecontrol and metering of food, beverage or other fluid materials into thecontainers.

[0008] Once the containers are filled the positive controlleddiscontinuous conveyor apparatus moves those filled first plurality ofcontainers to a sealing station while a second plurality of oriented,roughly sequenced containers are transported to the fill positionpreviously occupied by the first plurality of containers. At this pointthe screw conveyor again stops and the first plurality of containers arepurged of ambient air and sealed while the second plurality ofcontainers are being simultaneously filled. Once the filling of thefirst plurality of containers and the sealing of the second plurality ofcontainers has been completed the screw conveyor advances the firstplurality of containers to an inspection station for fill and sealinspection and defective containers are optionally marked while thesecond plurality of containers are sealed in the sealing station and athird plurality of roughly oriented containers that had been transportedto the fill station are simultaneously being filled while the screwconveyor remains stopped. At this point the first plurality ofcontainers, inspected for fill and seal requirements, could alsooptionally be removed at the completion of inspection by opening discarddoors at the bottom of the novel filling and sealing machine while thesecond plurality of containers are sealed and the third plurality ofcontainers are filled.

[0009] Once the filling of the third plurality of containers, thesealing of the second plurality of containers and the optionalinspecting and tagging of defective containers of the first plurality ofcontainers are completed the screw conveyor again turns to transport thefirst plurality of containers from the screw conveyor to be removed at adefective container removal station in the novel filling and sealingmachine or be discharged from the screw conveyor to be removed furtherdown the production line while the second plurality of containers aretransported to the inspection station, the third plurality of containersare moved to the seal station, and a fourth plurality of oriented androughly sequenced containers are moved to the fill station and the screwconveyor again stops. While the screw conveyor remains stopped all thepreceding steps are repeated on each new subsequent plurality ofcontainers. In the preferred application of the invention the fillingand sealing operations are provided for simultaneously on both sidesalong the axial length of a single screw conveyor while the screwconveyor is stopped. In the best mode inspection stations, rejectstations and other processing stations may be added along the axiallength of the screw conveyor.

[0010] The novel filling and sealing apparatus is able to achieve itsmultiple filling and sealing processes on both sides of a single screwconveyor as a result of the positive conveyor control forces maintainedat all times to provide precise positioning of the plurality ofcontainers resulting from the positive conveyor control of forcesexerted by the threads of the screw conveyor on the walls of thecontainer as well as the positive conveyor control of forces exerted onthe flat bottom of the container and the sides of the container throughthe use of guide rails and rods or bottom support plates in combinationwith the threads of the screw conveyor to at all times maintain positiveconveyor control forces on the containers along the axial length of thescrew conveyor.

[0011] The positive conveyor control forces in the preferred embodimentare maintained throughout the transport of the container by the screwconveyor in the novel filling and sealing apparatus which allowsadditional inspection, rejection and processing steps to be implementedwhile the containers are being filled and sealed in the novel fillingand sealing machine. These positive conveyor control forces in thepreferred embodiment are maintained at all times during thediscontinuous transport of the containers along the discontinuousoperation of the novel positive control conveying means of the novelfilling and sealing device of the novel production line.

[0012] The filled and sealed containers from the novel filling andsealing machine are thereafter transported to an accumulation conveyorand then to a sleever which sleeves the filled beverage containers whichare thereafter transported to a heat tunnel for the final shrinking ofthe sleeves to provide labeled beverage containers. The sleeve labeledcontainers are then transported to a novel straw applicator whichautomatically attaches covered straws to the outside of the beveragecontainers as the labeled beverage container passes by the novel strawapplicator apparatus. The straw applicator apparatus receives acontinuous band of straws, advances those straws, cuts the straws fromthe band into individual sealed straws and, through a combination ofvacuum and sequencing applies the individually wrapped straws to theoutside of the container as it passes by the novel straw applicatordevice.

[0013] The novel production line is controlled by a computer andsoftware which provides for the positive control of all phases of thenovel production line including the monitoring and control of theproduction line to reject improperly filled or sealed containers bycoordinating the sequencing of the containers in the novel automatedcontainer filling production line. As will be appreciated by thoseskilled in the art, the novel automated container filling productionline and method of the invention integrates and controls continuous anddiscontinuous conveyor operations in a plurality of production lines inwhich the infeed conveyor, feed and orientation conveyors andaccumulation conveyor are designed to operate continuously while thenovel filler and sealer machine of the novel production line operates ina discontinuous ‘stop and go’ operation. The sleevers, and heat tunnelsare also designed to operate in a continuous production process whilethe novel straw applicator apparatus includes a ‘stop and go’ operationin cutting and separating straws. These various operations areintegrated into a continuous conveying operation which are controlled bya computer and related software in a downstream flow effect which byback pressure sensing and control increases or decreases the speed ofthe continuous and discontinuous conveyor operations throughout thenovel production line.

[0014] 2. Description of Related Prior Art

[0015] The prior art includes numerous types of production lines,methods and apparatus for filling containers and provides theseapparatus and methods for discreet operations. The invention, incontrast to the batch and discontinuous prior art processes, provides afull and complete integration of continuous and discontinuous conveyorand filling operations to take unfilled, unoriented containers at oneend of the production line and provide filled, sealed and fullycompleted containers with a packaged straw applied to the outside of thefilled sealed containers at the other end of the production line.Further, the individual novel components of the novel production line,including the orientation conveyor component, the novel filling, sealingand screw conveying apparatus, the novel straw applicator, the novelambient air purging heat-sealing pistons, positive shut-off valves,straw applicator, conveyor belt and other subcomponents of the novelproduction line have not been shown or illustrated in the prior art.

[0016] More particularly, prior art relevant to the orientation conveyorcomponent of the novel production line include Gosney U.S. Pat. No.4,271,954 and Rheinstrom U.S. Pat. No. 2,183,433 which pertain to bottleorienting conveyor apparatus. In Gosney '954 unoriented bottles areobtained from a bin and oriented from an open end leading position to anopen end trailing position for subsequent filling utilizing cams andmechanical devices for conveying the oriented bottles. Rheinstrom '433provides for the division of oriented bottles in an ‘open end up’configuration into a plurality of production lines. Neither Gosney '954nor Rheinstrom '433 provide a conveying apparatus which receivesunoriented containers or bottles from a supply bin and utilizes pliantplates simulating the action of the human hand to orient and provide arough sequencing of the containers. Further neither Gosney '954 norRheinstrom '433 orients containers in a ‘bottom up’ ‘top down’configuration and, once oriented and sequenced, subsequently turns thecontainers to a ‘bottom down’ ‘top up’ configuration for introductioninto a filling and sealing apparatus.

[0017] Other prior art for conveying articles include Kontz U.S. Pat.No. 4,223,778 which pertains to a parison handling apparatus, Mezey U.S.Pat. No. 3,978,979 which pertains to a light bulb conveyor apparatus andDaleffe, et al. U.S. Pat. No. 3,517,797 which pertains to a threadbobbin tube alignment conveyor system. Kontz '778, Mezey '979 andDaleffe, et al. '797 do not provide for the utilization of pliant platessimulating the operation of the human hand for orienting and sequencingthe articles in the conveyor, nor for the complete turning of thearticles prior to their being introduced into a novel filling andsealing apparatus in the novel production line of the invention.Daleffe, et al. '797 does provide a conveying system which partiallyturns bobbins for subsequent stacking in an aligned position butDaleffe, et al. does not utilize pliant fingers simulating the action ofthe human hand in orienting and providing a rough sequencing of articlesin a production line utilizing continuous and discontinuous conveyingsystems.

[0018] Prior art relevant to the novel conveying, filling and sealingapparatus includes Heyne, et al. U.S. Pat. No. 2,571,036 and Martin etal. U.S. Pat. No. 4,947,979 which represent conveying devices utilizingspiral timing devices for advancing containers in a processing machine.In Heyne, et al. '036 the spiral timing device provides a continuousoperation of the spiral timing device in which the spiral timing devicesprovides for the spacing of the article necessary for the synchronizedfeed of the article and in Martin, et al. '979 the spiral timing deviceprovides a dwell for the containers at one or more work stations whilethe containers remain engaged between the rotating feed screws. UnlikeHeyne, et al. '036 and Martin, et al. '979 the present inventionprovides a positioning device rather than a pure timing device. Theinvention utilizes both sides of a screw conveyor and exercises positivecontrol over the containers on both sides of the screw conveyor toprovide multiple work stations along the length of the conveyor. Furtherthe screw conveyor of the invention operates in a start stop fashion anddoes not provide a dwell or a different sequencing for the containersfor only one work station.

[0019] The novel filling and sealing machine of the invention provides apositive control conveyor means to capture the sides of containersbetween threads of the screw conveyor and guide rails (or support platesat the sealing area) both at the sides and bottom to provide aconsistent spacing of containers in a discontinuous non-dwellingoperation in which the containers are advanced and stopped in aplurality of production lines at precise locations disposed insubstantially perpendicular alignment to the screw conveyor. The precisecontrol and stopping of the screw conveyor at simultaneous filling andsealing stations above the screw conveyor for the filling and sealing ofa plurality of containers is provided by the novel positioning screwconveyor apparatus of the invention.

[0020] Bausch, et al. U.S. Pat. No. 4,605,047 utilizes a conveyingdevice that starts and stops the advancement of containers in aproduction line. Bausch et al. '047, however unlike the presentinvention, does not utilize a conveyor device having uniform pitch alongthe conveyor worm and does not provide multiple work stations or provideconstant positive conveyor control forces over the container for both afill and seal position disposed axially along the length of the wormconveyor. In Bausch, et al. '047 the worm threads are not of consistentpitch since the worm threads include a rest zone to provide positioningof the articles below a filling place or utilizes a reverse turn of theconveyor to remove forces from the container. The Bausch, et al. '047worm threads may also utilize flat spaces or recesses in the worm whichreduce the radius of the worm over part of the circumference of the wormto provide a rest zone in the conveying apparatus.

[0021] In addition Bausch, et al. '047 does not provide the constantpositive control required for the simultaneous filling of one group ofcontainers on the conveyor line along with the simultaneous purging andsealing of another group of containers along the conveyor line as isaccomplished in accordance with the novel screw conveyor filling andsealing device of the invention. This difference is particularlyimportant where the filling and sealing operations require differentcontrol tolerances. More particularly, the tolerance for the fillingoperation is far less critical than for the simultaneous sealingoperation which in filling and foil sealing operations requires atolerance of about one thirty thousandth of an inch.

[0022] Other spiral conveying mechanisms such as Carter U.S. Pat. No.3,012,650 like Heyne, et al. U.S. Pat. No. 2,571,036 and Mihail U.S.Pat. No. 4,789,016 provide for the continuous movement of articles alongthe conveyor as opposed to the discontinuous advancement of articles toa plurality of independent work stations along the length of the screwconveyor. Further the invention, unlike the prior art, maintainspositive control over the container during their entire residency at thefill and seal positions in the screw conveyor which makes the multiplework stations possible utilizing the novel filler and sealer apparatusof the novel production line of the invention.

[0023] Prior art relevant to the novel straw applicator apparatus of theinvention includes Miller U.S. Pat. No. 3,189,171 which illustrates atelescoping straw (FIG. 2), without a poseable neck that is taped to thetop of a container. Miller does not illustrate a mechanism for attachingthe pre-packaged straw to the container. Other prior art which is morerelevant to the machinery for the attachment of the pre-packaged strawto a container includes Yokoyama U.S. Pat. No. 5,037,366, Hakansson U.S.Pat. No. 4,969,308, Wild U.S. Pat. No. 4,572,758 and Utsumi U.S. Pat.No. 4,384,915. Such prior art straw applicator apparatus typically relyupon drums (Yokoyama '366) and mechanical arms as illustrated byYokoyama '366 and Hakansson '308 to attach straws to containers. Wild'758 employs a mechanical plate to press straws up against the side ofthe container in a batch process.

[0024] The invention unlike the prior art is designed to apply straws ona conveyor assembly line utilizing a combination of elastomeric belts,one of which belt includes openings for holding pre-packaged straws in apredetermined position and a vacuum to hold the straw in the belt priorto its being attached to the container. The straw containing an adhesiveis then released around a roller disposed perpendicular to but parallelto the continuous travel of the conveyor on which the container isdisposed to provide an on demand straw application apparatus.

[0025] Other straw applicator devices such as Hakansson U.S. Pat. No.4,969,308 provides an intermittently pivotable mechanism to pick upindividual straws from a drum and then transfer the individual straws toa conveyor mechanism having a vacuum holding mechanism. The vacuumholding mechanism however transfers the straws to a mechanical pivotingarm on a chain to pressure position the individual straws oncontinuously moving containers. The present invention unlike Hakansson'308 applies straws on demand to containers on a conveyor belt utilizinga plurality of conveyor belts which utilizes a vacuum chamber incombination with a specialty designed elastomeric belt for holding thestraws until the straws are applied to the outside of the container.

[0026] Utsumi U.S. Pat. No. 4,384,915 employs a drum together with a camgripper with an electric heater to heatbond a straw to the outsidepackage as the package is moved on a continuous conveyor. The inventionunlike Utsumi '915 utilizes a combination of an elastomeric belttogether with a vacuum to apply the straw to the outside of thecontainer without the necessity of heat sealing the individual wrappedstraw to the outside of the container.

[0027] Unlike the prior art the novel system and method of the inventionprovides for the complete automation of a production line controlled bycomputer software which integrates continuous and discontinuousoperations and controls all aspects of the filling, handling, sealingand straw application to a container in combination with an on demandstraw application process without requiring exact mechanical timinglinks and without requiring a batch handling process. The novel methodand apparatus of the invention achieves its advantages through theapplication of a computer control system for increasing and decreasingvarious phases of the production conveyor systems by increasing ordecreasing various continuous and discontinuous processes in theconveyor flow by coordinating individual production rates based upondesign production flow rate and backlog at various stages of theproduction line.

[0028] As a result limitations exist in the prior art related toorientation and sequencing conveyors, filling sealing apparatus as wellas the apparatus for applying on demand straws to the outside of acontainer to provide a finished article. Further the prior art failed toprovide a fully automated, completely controlled production linefacility for taking unoriented containers, orienting and sequencingthose containers, filling and sealing those containers, as well asapplying sleeves, labels and applying a straw to the outside of thecontainer to provide a finished product in a fully automated andintegrated system to reduce the number of handling steps and provide ahygienic food handling production line which reduces the possibility ofcontamination of the food product through handling as well as providingan easy to clean, continuous production line for producing a filled foodcontainer.

[0029] There also exists a need in the prior art for a feed andorientation conveyor for hygienically and automatically handlingunoriented containers and orienting and providing a rough sequencing ofthose containers in a way that simulates the action of the human handwithout the necessity of human intervention to provide a hygienichandling of the containers and a rough sequencing of those containers ina plurality of individual production lines which can be fed into amachine for filling and sealing a food or other flowable or fluidproduct.

[0030] The limitations of the prior art also make it desirable toprovide a single filling and sealing machine which receives a pluralityof oriented containers in a plurality of production lines and advancesthose containers in a precise discontinuous conveying process whereby aplurality of the production line containers are precisely advanced andprecisely stopped at predetermined locations in the production line sothat one batch of a plurality of containers can be simultaneously filledwhile a second batch of containers in the same plural production linescan be simultaneously purged and sealed as the precisely controlledconveying mechanism remains stopped for a predetermined period of time.The positive control further allows for the simultaneous inspection andsimultaneous rejection of containers in a single production line thatallows a number of processing steps to be accomplished simultaneously.

[0031] The limitations in the prior art also have created a need for anovel straw applicator which positively engages a pre-packaged straw andapplies the pre-packaged straw to passing containers on a productionline in an on demand time basis to provide a final product. The novelstraw applicator can be controlled by the computer but in the best modeof the invention is a stand alone unit that applies straws on demand tofilled, sealed, inspected and sleeved containers. The novel strawapplicator includes a novel straw applicator belt for applying straws tofilled, sealed and labeled containers as they contact the novel strawapplicator belt.

[0032] The limitations in the prior art also have established the needfor an entire production line controlled by computer control toprecisely control the entire production line from the hygieniccollection of unoriented containers, the hygienic orientation andsequencing of those containers as well as the hygienic filling andsealing of these containers. The computer control of the production linealso provides for the control of the sleever for adding sleeves to thecontainer as well as the heat tunnels for firmly fixing the sleeve tothe container in the production line to result in a final product thathas been produced with minimum human contact in a hygienic productionline for providing a final food product. The computer control of theproduction line and software for maintaining the operation of the novelproduction line and novel orientation and infeed conveyors, filler andsealer apparatus and sleever and heat tunnels is achieved by utilizingbackflow pressure techniques which manage the entire production line ina real time or near real time mode by increasing or decreasing variousphases of the conveyor production line as it is needed to produce afinal packaged food product.

SUMMARY OF THE INVENTION

[0033] The invention provides a novel method and apparatus for acontainer filler production line which at one end takes unorientedcontainers and at the other end provides a final filled product thatincludes computer control of a conveyor line having continuous anddiscontinuous modes of operation as well as product flow rates. Thenovel production line and method of the invention include novelapparatus including a novel container unscrambler which hygienicallyhandles unoriented containers, a novel filler sealer machine whichhygienically fills and seals those containers, novel heat sealingambient air purging pistons, novel positive control shut-off valves,accumulation conveyors together with a computer which adjusts rates offlow between continuous and discontinuous production line operations inthe novel production line. A novel straw applicator and novel strawapplicator conveyor belt is also provided for applying straws in an ondemand time frame to the outside of the filled and sealed containers.The entire production line other than the novel straw applicator iscontrolled by computer and related software to integrate and vary thespeeds of continuous and discontinuous conveying portions of theproduction line to maintain flow from the container unscrambling deviceto the packing of the filled, sealed, inspected and consumer packedproduct into shipping cartons. In addition the features and advantagesof the novel production line include the hygienic handling of thecontainers from the time they are received from the container bin to thepackaging of the final product by eliminating human intervention in theproduction process while providing for ease of cleaning of variouscomponents in the novel production line.

[0034] The container unscrambler is designed to take unorientedcontainers from a supply bin and orient and roughly sequence thosecontainers utilizing pliant plates which simulate the action of a humanhand in orienting those containers. In one embodiment of the inventionthe rough sequencing of the oriented containers are oriented in a ‘topup’ configuration where the containers have a top of a cross-sectionalconfiguration that is larger than the cross-sectional configuration ofthe bottom half of the container. In the preferred embodiment of theinvention containers having a larger bottom half cross-sectionalconfiguration are first oriented in a ‘bottom up’ ‘top down’configuration. The ‘bottom up’ ‘top down’ oriented containers are thenroughly sequenced and advanced to a turning plate for turning thecontainers from a ‘bottom up’ ‘top down’ configuration to a ‘bottomdown’ ‘top up’ configuration before they are deposited through a dropchute on to an infeed conveyor and then to the novel filling sealingmachine. In both embodiments of the invention the bottle unscrambler andorientation conveyor provides a plurality of production lines which aredesigned to hygienically handle, orient unoriented conveyors and providea rough sequencing of the containers for the novel filler sealermachine. The novel container unscrambler is designed to provide a roughsequencing utilizing a plurality of resiliently mounted platessimulating the action of the palm of the hand and pivotable rods thatsimulate the action of the fingers in providing a rough sequencing ofcontainers for the novel filler sealer machine.

[0035] The novel container unscrambler is, in the preferred application,designed to provide four separate production lines, each capable ofoperating independently and each having a clutch assembly to allow themto operate at a different rate of speed or to be individually stopped.This independent rate of operation is achieved through sensors, acomputer and computer-controlled clutches which individually control thespeed of each of the lines based upon downfeed sensors which increase orslow the rate depending upon the flow characteristics of the containersin that production line and the specific needs of the production linewithout the necessity of shutting down the entire production line.

[0036] The conveyor action in the bottle unscrambler is provided byelastomeric conveyor belts connected to pulleys that support either sideof a container and preferably a container of a cylindrical configurationhaving a base larger than the top and advance the container along theconveyor by means of the elastomeric belts. The elastomeric beltsadvance and provide a rough sequence for the containers and in thepreferred embodiment orient in a ‘bottom up’ ‘top down’ configurationuntil they are advanced to a turning plate which turns the containersfrom a ‘bottom up’ ‘top down’ position to a ‘top up’ ‘bottom down’configuration just before they are deposited through a drop chute forplacement on an infeed conveyor to the novel filler and sealer machine.The infeed conveyor in the preferred embodiment is also connected andutilized by the computer similar to the accumulator conveyor to increaseand decrease the speed of the orientation conveyor and elevator conveyorto provide additional control over the speed of the novel productionline.

[0037] The bottle unscrambler and orientation conveyor in bothembodiments obtain unoriented containers from a supply hopper by theutilization of an inclined elevator conveyor having container supportplates which remove cylindrical containers from a supply hopper. Theremoved containers are randomly oriented on the support plates which mayinclude an excess of containers on the container support plates. Excesscontainers on a particular support plate are removed from the inclinedelevator conveyor by means of a scraper plate which prevents too manycontainers from being fed into an infeed hopper connected to theorientation conveyor.

[0038] The infeed hopper of the orientation conveyor receives theunoriented containers from the inclined elevator support plates andbegins the process of orienting and providing a rough sequencing of thecontainers in the preferred embodiment in a ‘bottom up’ ‘top down’configuration in a plurality of parallel production lines in theorientation conveyor. The containers deposited in the infeed hopper bythe combination of gravity and conveyor action of the elastomeric beltsof the orientation conveyor allows containers to either fit into theplurality of conveyor lines in a ‘top down’ ‘bottom up’ configuration orfall between the plurality of lines when too many containers are bunchedup at one time in the elastomeric belts and in the infeed hopper. Theconveying motion of the elastomeric belts allows the containers toorient themselves before flowing out of the infeed hopper along theplurality of production lines.

[0039] Containers that are properly oriented in the preferred embodimentin a ‘bottom up’ configuration or in the alternative embodiment in a‘bottom down’ configuration may also be bunched up too close together inany one production line to be properly sequenced for the filling andsealing machine further down the production line. In such case aplurality of pliant plates which simulate the action of human hands pushexcess containers along the orientation conveyor line until they havethe proper rough sequencing and spacing between the containers as theymove along the orientation conveyor. Drop chutes are provided at the endof each of the production lines of each of the orientation conveyors. Inone embodiment a plurality of drop guide plates assist in guidingcontainers in a ‘top up’ ‘bottom down’ orientation into the drop chutes.In the preferred embodiment ‘bottom up’ ‘top down’ oriented containerscontact turning plates before being deposited into the drop chutes toprovide containers in the ‘top up’ ‘bottom down’ orientation for thenovel filler and sealer machine. The novel feed and orientationconveyors also include individually controllable means that can slowdown or stop the conveying action of a particular lane depending uponthe flow characteristics of the oriented containers through the novelfilling and sealing apparatus and flow characteristics and requirementsof the various production lanes down to the completed filled, sealed,labeled and straw containing product.

[0040] The novel filling and sealing apparatus includes an infeedconveyor for feeding the oriented and roughly sequenced containers tothree pair of screw conveyors for positively engaging and then preciselymoving a plurality of containers in the novel filler sealer apparatus.The screw conveyors are preferably made of Delrin® and have a uniformthread angle from end to end which together with guide rails andcontainer biasing rods and flat plates in the seal position preciselyposition and move a plurality of containers through the novel fillingsealing machine. The uniform thread angle of the screw conveyor providesa precise positioning means for a plurality of work stations disposed insubstantial perpendicular alignment with spaces between the threads ofthe screw conveyors, when the screw conveyers are stopped, at aplurality of work stations disposed along the length of the novel screwconveyors of the filler sealer machine.

[0041] The novel filling sealing machine turns the screw conveyors in adiscontinuous operation so that a plurality of containers move in aspaced relationship defined by the uniform spiral angle of the threadsof the screw conveyor to precise positions and work stations within thenovel filler sealer machine. Teflon® guide rails are provided on thesides opposite the screw conveyor and base support rods or plates at theseal area both reduce friction for plastic containers and aid in theprecise positioning and movement of the containers through the machineand during the stopping and starting of the screw conveyor.

[0042] The screw conveyor provides a plurality of lanes in whichcontainers along the length of the screw conveyor are in a precisepositional relationship to one another and in relation to the spiraldistance between each axial section of the screw conveyor. This spacedrelationship allows the incremental advancement of the screw conveyor toprecisely move a plurality of containers and stop the motion of theplurality of containers in precise positions along the length of thescrew conveyor. This also allows a plurality of containers along thelength of the screw conveyor to be filled in one portion along thelength of the screw conveyor while another group of containers furtheralong the length of the screw conveyor are simultaneously purged andsealed at another area along the length along the screw conveyor.Associated with the filling area are a plurality of sensors that sensethe presence of a container in the screw conveyor corresponding to thefill position of each container. In the event a container is not presentat a particular fill area, the fill meter piston for that position isnot activated to prevent spilling or wasting fill materials.

[0043] In one embodiment of the invention the screw conveyor is turnedto advance containers to a fill station and advance containers at thefilling station to be advanced to a fill inspection station while thesealed containers are moved to a seal inspection station and previouslyinspected containers are removed from the production line at a rejectstation that failed either seal inspection or fill inspection. At thispoint the new set of containers are filled, the previously filledcontainers are inspected for fill, the previously inspected containersfor fill are being sealed, and the containers at the reject station arebeing removed for improper fill or seal. After the screw conveyor againstarts, it advances a second set of new containers to the filling area,the filled containers to the inspection area, the inspected containersto the seal and the sealed containers to the seal inspection area,andthe containers previously inspected for fill and seal are moved to areject area to be rejected for improper fill or seal. When the screwconveyor again turns, the containers having a proper fill and seal areconveyed from the novel filling and sealing machine while the precedingcontainers are moved to the new stations in a continuation of thefilling sealing production process.

[0044] The novel screw conveyors and their incremental advancement andpositioning of the containers at various stages along the novel fillingand sealing apparatus of the invention allows the novel apparatus to bedivided into a plurality of precise work stations disposed in axial andsubstantially perpendicular alignment to the screw conveyor. The firstwork station is the filling station which provides for the precisemetering of a beverage, food material such as baby food, yogurt or ayogurt beverage or other flowable product into the container at thefilling portion of the screw conveyor.

[0045] In a further embodiment of the invention multiple inspection andrejection positions can be provided where containers are filled and afew turns of the screw conveyor advances a new set of containers to thefill station and the filled containers to an inspection area where thefilled containers are inspected with sensors to determine whether theyhave been filled to a proper level. While the filled containers arebeing inspected for proper filling the new set of containers advanced tothe filling area are being simultaneously filled.

[0046] The novel screw conveyor then turns again and then stops again toadvance a new set of containers to the fill area, the filled containersto the inspection area and the inspected containers to a drop area wheredrop doors open to drop one or more of the containers into a discardbin, if any of the containers have not been filled to the proper level.Thereafter the novel screw conveyor turns again to advance a new set ofcontainers to the fill area, filled containers to the inspection areaand precisely move in position only the properly filled containers to asealing station which purge the properly filled containers of ambientair and replaces the ambient air with nitrogen, moves a shuttle plate tomove sealing foil to a position above only the properly filledcontainers present in the production line and heat-seals the foil to thecontainer while the previously filled and inspected containers areplaced over the reject door and rejected if they have not been properlyfilled, the previously filled containers are being inspected and the newset of containers are being filled.

[0047] Thereafter the screw conveyor is turned again to move the sealedcontainers to a seal inspection station to determine whether the filledand sealed containers have been properly sealed, the previously properlyfilled containers remaining over the discard doors of the conveyor arethen moved to the sealing portion of the conveyor, the containers at thefilling inspection position are advanced to the fill drop position,containers in the fill area are moved to the fill inspection area, and anew group of containers are moved into position under the filling area.

[0048] The screw conveyor stops and simultaneously the containers in theseal inspection position are inspected for proper seal, containers inthe seal position are sealed, containers in the fill drop station thatfailed inspection are dropped through drop doors, containers in the fillinspection position are inspected for proper fill and containers in thefill position are filled.

[0049] Thereafter the screw conveyor turns again and advances thecontainers over the seal inspection area to a seal reject door position,the containers in the seal position are advanced to the seal inspectposition, the containers remaining over the fill drop station areadvanced to the seal position, containers in the fill inspect positionare moved to the fill drop position, the previously filled containersare moved to the fill inspection position, and a new set of containersare moved to the fill position. The screw conveyor again stops and anycontainer above the seal reject door failing seal inspection is removedthrough the seal reject door, containers in the seal inspect positionare inspected for proper seal, containers in the seal position aresealed, any container that failed fill inspection above the fill dropdoor is removed, containers in fill inspection position are inspectedand containers in the fill position are filled.

[0050] The screw conveyor turns again and advances containers remainingover the seal reject door that have a proper seal out into anaccumulation conveyor and the previously seal inspected containers aremoved into the seal rejection area, the previously sealed containers aremoved to the seal inspection area, the containers over the fill rejectdoors that have not been discarded over the reject area are advanced tothe sealing area, and the previously fill inspected containers are movedover the fill reject area and the previously filled containers are movedto the inspection area, and a new group of containers are placed underthe filling portion of the screw conveyor. This process continues as thescrew conveyor incrementally advances oriented containers through thenovel filling and sealing apparatus.

[0051] The novel filling and sealing apparatus includes at the fillingstation a clean in place apparatus for hygienically cleaning the fillerportion of the novel filler and sealer apparatus. The filler portion ofthe novel filler and sealer apparatus includes a food product or fillreservoir connected to a piston cylinder combination that preciselymeters the fill product into the containers by advancing a taperedpiston to a mating tapered valve seat to provide a positive shut-offvalve for depositing the food or fill product into the containers.Thereafter the positive shut-off valve is closed with the mating of thetapered piston to the tapered valve seat and the fill reservoir pistonis retracted to its fill position and more product is placed into theproduct reservoir piston cylinder combination.

[0052] A further embodiment of the novel positive shut-off valve isprovided for dispensing fluid food products that includes a variety ofnozzles for precisely metering and controlling the dispensation of foodproducts while minimizing dripping, splashing and sloshing of the fluidfood product. The novel positive control shut-off valve includes ahousing having a flowable product inlet intermediate the ends of thepositive control valve. At one end of the positive control valve is anair line fitting communicating with a plenum on one side of a diaphragmand at the other side of the diaphragm an inlet for the productdispensing nozzle. Disposed at the other end of the positive controlshut-off valve is a nozzle for dispensing food product having a channelcommunicating with the nozzle inlet and the diaphragm.

[0053] The novel positive shut-off valve operates by having a flowablefood product pumped in the flowable product inlet which flows into thehousing, past the diaphragm and into the nozzle inlet and out the nozzleoutlet into the container. Once the metered amount of fluid has beendispensed air pressure is applied to the plenum on the other side of thediaphragm to close off the nozzle inlet and prevent further product fromflowing through the nozzle. The novel positive control valve includes avariety of nozzles for metering a variety of flowable food products thataccommodate a variety of viscosities.

[0054] A novel clean in place apparatus allows the pistons and cylindersto be cleaned by pumping cleaning solutions through the fillermanifolds, filler valves and to the filler pumps and positive shut-offvalves before the fluid is returned to the CIP-manifold. The closed loopclean in place system is also computer-controlled to provide for theperiodic cleaning of the novel filler apparatus. Similarly the sealerportion of the machine is designed to allow the periodic pivoting awayof the heat-sealer and purge pistons for cleaning.

[0055] The sealing portion of the novel filling and sealing apparatusemploys a multifunctional heater head which includes a nitrogen port forpurging ambient air from the containers disposed below the heater headbefore a shuttle plate bearing a foil is placed directly above thecontainer. Once the shuttle place is in place directly under the heaterhead and over the container the heads are extended downwardly pushingthe foil through the shuttle plate and applying it to the containerpositioned directly below the foil opening in the shuttle plate.Thereafter, for an appropriate amount of time, the heater heads areactivated to heat-seal the foil to the container to seal the container.The heater heads are designed to retract and cooperate with theretraction of the shuttle plate in such a manner as to turn a tab on thefoil over the top of the container which later is surrounded by aplastic sleeve applied by the sleever and a straw is applied to the sideof the sleeve by the novel straw applicator apparatus.

[0056] The novel screw conveyor precisely and discontinuously moves thecontainers in a start stop discontinuous operation that is sufficient inthe preferred embodiment of the invention to position the container overthe heat-sealing pistons that require a tolerance of about {fraction(1/30,000)} of an inch. This precise tolerance is necessary forheat-sealing foil closures to plastic containers in accordance with thepreferred embodiment of the invention. The preferred application of theinvention is for filling yogurt beverage containers. As will berecognized by those skilled in the art many types of sealing apparatuscan be utilized such as the application of screw caps, crimped caps andother types of closure devices can be applied where the tolerances arenot as close as in the utilization of a heat-seal foil in accordancewith the preferred embodiment.

[0057] After the filled and sealed container exits the novel fillersealer apparatus the container is preferably deposited upon anaccumulation, conveyor which functions as a controller conveyor.Depending upon the number of filled containers on the accumulationconveyor, the speed of the feed in the orientation and infeed conveyorsand the delay period the discontinuous operation of the screw conveyoris stopped can be increased or decreased within limits. The entireproduction line can be integrated by a computer and time rates of thevarious production phases modified based on flow and backlog of thecontainers. Containers are transported from the accumulation conveyor toa sleever which applies a label or sleeve containing a label around thefilled container. Once the sleever applies the label to the container,the container is transported to a heat tunnel which shrinks the sealonto the container. The sealed and labeled container is then transportedto the novel straw applicator.

[0058] The novel straw applicator automatically applies straws on demandto the outside of the container as the container passed on a conveyorpast the novel straw applicator. The novel straw applicator is disposedperpendicular to the conveyor production line and secures anindividually wrapped straw to the outside of the filled and foil-sealedcontainer. The novel straw applicator receives a band of individuallywrapped straws in a cellophane band and first tensions the band beforethe band is introduced to the novel straw applicator conveyor belt ofthe novel straw applicator apparatus. At the introduction of the strawsto a set of opposing conveyors, the straws are drawn in the band past afirst set of laterally adjacent rollers which are connected to a secondset of laterally adjacent rollers by two separate conveyor bands. At thefirst set of adjacently disposed conveyor rollers an adhesive tape isapplied to one side of the band of straws to provide a sticky adhesivebacking from a roll of tape which may be disposed in the housing of thetensioning element of the novel straw applicator device.

[0059] The straws are advanced in the first set of conveyors to a strawband cutter blade which severs the straws from the band and advances theindividually wrapped straws to a novel straw applicator conveyor beltwhich has a plurality or straw applicator notches on one side and on theother side a series of timing notches together with vacuum ports forholding the individually cut straws in the plurality of straw openingswhile a vacuum box provides a vacuum for securely holding theindividually cut straws with the adhesive as it travels along the strawapplicator conveyor. The novel straw applicator conveyor belt isdisposed between the second pair of opposing pulleys in the strawapplicator conveyor to a straw applicator release pulley and thetensioning idler pulley. The novel straw applicator conveyor beltadvances the cut straws to the application pulley at which point thevacuum is released and at the same time a filled and sealed containerpasses adjacent to the novel straw applicator conveyor belt whichresults in the adhesion and transfer of the adhesive tape backed strawto the side of the container to provide a final filled and sealedproduct with a straw applied to the outside surface of the filled andsealed container.

[0060] Associated with the straw applicator is a sensor to determinewhether a filled and sealed container is properly sequenced with theoperation of the straw applicator conveyor belt. The sensor determineswhen a container is in a proper sequenced position upstream andsynchronously and on demand starts the straw applicator conveyor belt totime the release and attachment of the straw to the filled and sealedcontainer. Once the sealed straw is applied to the outside of thecontainer the container is ready for packaging and shipment.

[0061] The novel method and apparatus for the automated containerfilling and sealing production line produces a filled, sealed andpackaged container from a group of unoriented containers at one end withthe minimum intervention of human handling and processing. The novelsoftware provides for the fully automated process by integratingcontinuous and discontinuous conveyor processes for assuring containershave been properly filled and sealed in the automated productionprocess. In addition the novel container filling, sealing and handlingequipment of the invention provides for easy cleaning and hygienicproduct handling in accordance with the highest food handling qualitystandards.

[0062] The automated production line integrates continuous anddiscontinuous processes together with the rejection of containers notmeeting specification to assure the only containers meeting productstandards are further processed in the novel production line to conservematerials and increase the quality control of the finished product.These advantages are provided in a computer controlled integratedproduction line to provide a continuous production process fromcontinuous and discontinuous variable rate production processesutilizing continuous and discontinuous variable rate conveyor productionlines that provide the highest standards of quality control at variousstages of the filling and sealing operation.

BRIEF DESCRIPTION OF THE DRAWINGS

[0063] The objects and advantages of the invention will become furtherapparent to those skilled in the art from the following detaileddescription of the invention when read in conjunction with theaccompanying drawings in which:

[0064]FIGS. 1A and 1B are side elevational views of the novel productionline in accordance with the best mode of the invention;

[0065]FIG. 2 is a side elevational view of the novel containerorientation apparatus including an elevator infeed conveyor constructedin accordance with the invention;

[0066]FIG. 3 is an elevational view of the novel container orientationapparatus in accordance with the best mode of the invention;

[0067]FIG. 4 is an elevational view of the infeed hopper area of thecontainer orientation apparatus;

[0068]FIG. 5 is an elevational view of the novel container orientationapparatus taken along the line 5-5 of FIG. 4;

[0069]FIG. 6 is an elevational view of the novel container orientationapparatus taken along the line 6-6 of FIG. 3 without a turning plate anddrop chute;

[0070]FIG. 7 is an elevational view of the pliant orienting fingers ofthe novel container orientation apparatus;

[0071]FIGS. 8 and 8A are side elevational views of the novel orientationconveyor in which FIG. 8 illustrates the preferred embodiment with theturning plate and drop chute portion of the novel container orientationapparatus and FIG. 8A illustrates the drop guide plates and drop chuteportion of an alternative embodiment of the novel container orientationapparatus;

[0072]FIG. 9 is a side elevational view of the novel filling and sealingapparatus of the invention;

[0073]FIG. 10 is a top plan view of the novel screw conveyor layout inaccordance with the preferred embodiment of the invention illustratingcontainer sensor areas, filler areas, fill inspect areas, seal areas,seal inspect areas and fill and seal reject areas of the invention;

[0074]FIGS. 10A and 10B (schematic) are top plan views of an alternativeembodiment of the invention illustrating container sensor areas, fillareas, fill inspection areas, fill reject areas, seal areas, sealinspection and seal reject areas in accordance with an alternativeembodiment of the invention;

[0075]FIG. 11 is a side elevational view from the input end of the novelscrew conveyor layout of FIG. 10;

[0076]FIGS. 12 and 12A (schematic) are top plan views of a screwconveyor layout in accordance with an alternative embodiment of theinvention utilizing filler areas, seal areas and inspection areas of thenovel filler sealer machine of the invention;

[0077]FIG. 13 is a side elevational view of an alternative embodiment ofa screw conveyor that provides for the removal through reject doors ofcontainers having a too larger than the bottom in accordance with theinvention;

[0078]FIG. 13A is a side elevational view of an alternative embodimentof a screw conveyor that provides for the weighing of containers inaccordance with the invention;

[0079]FIGS. 13B and 13C are alternative embodiments utilizing a screwconveyor for simultaneously filling and sealing containers in accordancewith alternative embodiments of the invention;

[0080]FIG. 14 is a side view from the input end illustrating therelationship between the container, screw conveyor, guide rails andsupport rods in accordance with the preferred embodiment of theinvention;

[0081]FIG. 15 is a side elevational view of a mechanism for activating areject door in accordance with the preferred embodiment of theinvention;

[0082]FIG. 16 is a side elevational view illustrating the fillerassembly of the novel filler sealer machine of the invention;

[0083]FIG. 16A is a side elevational view of a novel positive shut-offvalve constructed in accordance with the invention;

[0084]FIGS. 16B, 16C and 16D are alternative embodiments ofcross-sections of nozzles for the novel positive shut-off valve of FIG.16A;

[0085]FIG. 17 is a cleaning fluid circulation flow diagram of the cleanin place system which periodically provides for the circulation of acleaning fluid through the piston and cylinder and positive shut-offvalve to clean the novel filler sealer machine;

[0086]FIG. 18 is a side elevational views of the pick and place andshuttle plate mechanisms for advancing a foil to a container at thesealing area;

[0087]FIGS. 18A, 18B, 18C, 18D and 18E are schematic side elevationalviews illustrating the operation of the pick and place and shuttle platemechanisms for advancing a foil to a container at the sealing area;

[0088]FIG. 19 is an input side elevational view of FIG. 18;

[0089]FIGS. 20 and 20A (schematic are side elevational views of thepivotal heat-sealing and ambient air purging assembly of the novelfilling and sealing apparatus of the invention;

[0090]FIGS. 21, 21A, 21B, 21C, 21E, 21 and 21F (21A-21F schematic) areside elevational views of a novel heat-sealing ambient gas purgingpiston of the invention;

[0091]FIG. 22 is an exploded side view of the preferred embodiment ofthe heat-sealing ambient air purging piston of the inventionillustrating a pivot bearing attachment for the increasing themaneuverability of the novel piston;

[0092]FIGS. 22A, 22B, 22C and 22D are alternative embodiments of pivotbearings for increasing maneuverability of the novel heat-sealingambient air purging piston of FIG. 22;

[0093]FIG. 23 is a side elevational view partly is section illustratingthe advantages of the novel heat-sealing ambient air purging pistonutilizing pivot bearing of the preferred embodiment of the invention;

[0094]FIG. 24 is a side elevational view illustrating an alternativeembodiment of the invention providing for the sealing of containers witha crimp seal;

[0095]FIG. 25 is a side elevational view illustrating the utilization ofa screw cap seal application of the invention;

[0096]FIG. 26 is a top plan view of a flow regulating conveyor withsleevers and straw applicators in the novel production line of theinvention;

[0097]FIG. 27 is a top plan illustrating the operation of the flowregulating conveyor in the novel production line of the invention;

[0098]FIG. 28 is a top plan view similar to FIG. 27 illustrating theoperation of the flow regulating conveyor in the production lineshutting off the flow production lines of the right side of theconveyor;

[0099]FIG. 29 is a top plan view similar to FIG. 27 illustrating theshutting down of the center lanes of the flow regulating conveyor in thenovel production line of the invention;

[0100]FIG. 30 is a top plan view similar to FIG. 27 illustrating theshutting down of the left lanes of the flow regulating conveyor;

[0101]FIGS. 31 and 31A (31A enlarged without housing) are top plan viewsof the novel straw applicator illustrating the straw applicator andassociated tension housing (FIG. 31) of the straw applicator of theinvention;

[0102]FIGS. 32 and 32A (32A enlarged) are side elevational views of thenovel straw applicator of FIGS. 31 and 31A;

[0103]FIGS. 33 and 33A (33A enlarged) a rear elevational view of thenovel straw applicator of FIG. 31;

[0104]FIG. 34 is a side elevational view of the knife assembly forcutting individually wrapped straws from a band of straws;

[0105]FIG. 35 is a top plan view of tie straw tensioning and sequencingapparatus of the novel straw applicator;

[0106]FIG. 36 is a side view of the straw tensioning and sequencingdevice taken along line 36-36 of FIG. 35;

[0107]FIG. 37 is a perspective view of the straw applicator belt of thenovel straw applicator of the invention;

[0108]FIG. 38 is a top plan view of the straw applicator belt of FIG.37;

[0109]FIG. 39 is a side elevational view of the outside of the strawapplicator belt of the novel straw applicator;

[0110]FIG. 40 is an inside side view of the straw applicator belt of thenovel straw applicator of the invention;

[0111] FIGS. 41A-F is a diagram of the computer logic program foroperating the novel filler sealer apparatus of the invention;

[0112]FIG. 42 is a time operation sequence chart illustrating timeoperation periods for the novel filler sealer apparatus;

[0113] FIGS. 43A-C is a diagram of the computer logic program foroperating the novel production line of the invention;

[0114]FIG. 44 is a top plan view illustrating the novel computercontrolled production line including the carton packaging end of thenovel production line;

[0115] Picture 1 is a photograph of a prior art packaged product with afolded straw;

[0116] Picture 2 is a photograph of the prior art product of Picture 1without the straw and sleeve illustrating the prior art sealed andcrimped foil seal;

[0117] Picture 3 is a close-up view of the prior art crimped foil seal;

[0118] Picture 4 is a photograph of the new packaged product with anattached telescoping straw produced in accordance with the best mode ofthe invention;

[0119] Picture 5 is a photograph of a new packaged product without thestraw and sleeve illustrating the seal and crimped foil of the novelproduct produced in accordance with the invention; and

[0120] Picture 6 is a close-up photograph illustrating the crimped foiland seal of the novel product produced in accordance with the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0121] The invention pertains to a novel integrated automated productionline having continuous and discontinuous conveyor operations integratedinto a continuous production line which takes randomly orientedcontainers from a supply hopper, orients and roughly sequences thosecontainers in a continuous conveyor operation and fills and seals thosecontainers in a novel filler sealer machine utilizing a screw conveyoroperating in a discontinuous conveying action which then deposits thosefilled and sealed containers on an accumulation conveyor which providesinformation to a computer for regulating the-entire production line. Thefilled and sealed containers are transported from the accumulationconveyor to a sleeving device for applying sleeves, optional heattunnels for shrinking the plastic sleeves and a novel straw applicatorwhich applies a pre-packaged straw to the outside of the filled, sealedand labeled container. The novel automated production line havingcontinuous and discontinuous conveyor operations is integrated into acontinuous production operation utilizing computer software whichobtains information at various points in the production line fromvarious types of accumulation conveyors to increase and decrease variousprocesses and control the operation of the production line at everystage of the container filing sealing operation.

[0122] The novel integrated production line includes novel devices forthe filling and sealing operations together with the computerintegration of those devices into a production line designed forcontinuous production. The novel devices incorporated into the novelproduction line include a novel orientation conveyor for orientingcontainers, a novel filler sealer screw conveyor device which isdesigned for simultaneously filling and sealing operations each time thescrew conveyor is stopped and novel ambient air purging heat-sealingpistons, a novel positive control shut-off valve and a novel strawapplicator apparatus and novel straw applicator belt. In the preferredembodiment of the invention the positioning screw conveyor also providesfor the simultaneous inspection of the filled and sealed containers andin the best mode of the invention the rejection of any improperly filledand sealed containers before the improperly filled or sealed containersare further processed down the production line. In addition to the novelorientation conveyor and filling sealing apparatus, a novel strawapplicator is provided in the production line to automatically attach anindividually wrapped telescoping straw to the outside of the containerto complete the production process of the invention. The novel strawapplicator includes sensors and sequence timing devices to deliver apre-packaged straw cut from a continuous band having an adhesive appliedto one side for attachment to the filled and sealed and packagedcontainer at the end of the novel integrated production process.

[0123] The invention is a product of an extensive research anddevelopment investigation into providing a fully automated productionline integrating continuous and discontinuous conveyor operations toprovide a fully automated hygienic production device meeting the highestrequirements of the food processing industry. The invention provides foran ease of cleaning parts in direct contact with food materials as wellas for the ease of cleaning all portions of the production line. As aresult all of the parts which come in contact with food materials arecomposed of high quality stainless steel, plastic and other materialsthat can be easily cleared in the production process. The novelintegrated automated production line as a result simulates themechanical equivalents of the human hand at various stages in theproduction process without introducing the disadvantages ofcontamination by human handling.

[0124] The novel automated integrated production line and the novelfiller sealer apparatus were developed to provide a fully automatedcontainer filling production line which is compact and includes a numberof processing stations for simultaneously filling, sealing, inspectingand, in the best mode, discarding containers that do not meet inspectionrequirements. The novel filler sealer machine is particularly adapted tofood containers that are filled with liquid or semi-solid food materialssuch as puddings, pie fillings, baby food, beverages and other types offluid food material which can be metered into a container and sealed andthen inspected on a fully automated container filling and sealingproduction line.

[0125] In the best mode of the invention the filler sealer machine andorientation conveyor are designed to handle containers having a base ofa larger size than the rest of the container. In the best mode thecontainer can have any type of cross-sectional configuration as long asthe outside upper portion of the container is not larger than the sizeof the base. This application of the invention allows containers to notonly be filled, sealed and inspected but also rejected in the novelcontainer filler and sealer apparatus in accordance with the best modeof the invention. In accordance with other embodiments of the inventionthe novel container filler sealer machine of the invention is adaptableto fill and seal all types of containers and provide for the rejectionof those containers by utilizing either a modified screw conveyor in thenovel filler sealer machine or provide for the rejection of faultycontainers outside of the novel filling, sealing and inspecting machineby providing a means for removing containers that did not meetinspection requirements somewhere further down the production line.

[0126] While the invention is applicable to all types of productionlines for the handling of foods, beverages, pie fillings, baby food andother types of fluid materials the invention will be hereinafterdescried with respect to its best mode which pertains to a yogurtfilling production line and, more particularly, to a yogurt drinkfilling production line in which randomly oriented containers are takenfrom one end of the production line and fill, sealed, labeled andprovided with a pre-packaged straw attacked to the outside of thelabeled container at the other end of the production line.

[0127] Referring now to FIGS. 1A and 1B the novel integrated productionline 10 is illustrated having at one end a supply hopper 12 having aplurality of randomly oriented containers 14 for filling, sealing,inspecting and completing in accordance with the invention. Randomlyoriented containers 14, as illustrated in FIG. 5, preferably have a base16 with a flat bottom 18. The base 16 of the container is preferably ofa size greater than the open filling end 20 so that the container can befilled, sealed, inspected and is capable of being rejected while thecontainer is on the novel filler sealer positioning screw conveyor aswill be described hereinafter in greater detail.

[0128] Referring again to FIGS. 1A and 2 the supply hopper 12 isconnected to an elevated feed conveyor 22 having a plurality ofcontainer transport plates 24 for removing randomly oriented containers14 from supply hopper 12. Attached to the side of elevated feed conveyor22 is a spring-mounted removal plate 26 which pivotally moves inresponse to the conveyor action of container transport plates 24 toremove excess containers 28 from the container transport plates 24before the randomly oriented containers 14 are deposited in infeedhopper 30.

[0129] Referring now to FIGS. 2-8 the novel orientation conveyor 32 isillustrated connected to elevated feed conveyor 22. As randomly orientedcontainers 14 are gravity fed into infeed hopper 30 they may free-fallbefore contacting a plurality of lane divider plates 34 which define aplurality of production lines 36, 38, 40 and 42 (FIG. 5). Alternativelythe container may contact sloping end plate 44 or housing wall 46 beforefalling into the plurality of production lines 36, 38, 40 and 42.

[0130] Once the plurality of containers have entered the plurality ofproduction lines 36-42 by the action of gravity, the plurality of lanedivider plates 34 and the conveying action of laterally opposingelastomeric belts, the container 14 falls between a pair of laterallyopposing elastomeric belts 48 and 50 to capture base 16 of container 14to orient the container between elastomeric belts 48 and 50 aselastomeric belts 48 and 50 continuously travel along the length of theconveyor. In this embodiment of the orientation conveyor the containersare transported in ‘bottom up’ ‘top down’ orientation to a plurality ofturning plates 54 (FIG. 8) which terminate in plurality of drop chutes56. The plurality of turning plates turn the ‘bottom up ‘top down’oriented containers 52 to a ‘bottom down’ ‘top up’ orientationcontainers 58 which are deposited on continuously moving infeed conveyor60.

[0131] Orientation conveyor 32 provides a rough separation or sequencingin the preferred embodiment of ‘bottom up’ ‘top down’ orientedcontainers 52 where containers have a base 16 are filled and sealed inthe novel filling and sealing screw conveyor apparatus which includes arejection door for rejecting improperly filled and sealed containers.However, where an oriented and rough sequenced container 57 (FIG. 8A) isoriented which has a bottom 59 smaller than the top 61 with an opening63 is filled and sealed in the novel filler sealer screw conveyorapparatus of the invention the plurality of turning plates 54 arereplaced by a plurality of drop guides 65 which stabilize bottom 59 ofcontainer 57 to maintain the ‘bottom down’ ‘top up’ orientation ofcontainer 57 into and through drop chute 56. In such applicationsorientation conveyor 32 orients the containers in a ‘bottom down’ ‘topup’ configuration utilizing the novel pliant plates and pliant rodssimulating the action of the human hand to provide rough sequencing ofthe oriented containers. In both embodiments of the novel orientationconveyor all the components are the same except for the utilization of aplurality of drop guides 65 in place of the plurality of turning plates54 to accommodate containers having a top larger than the bottom. Themethod of operation of both embodiments of the novel orientationconveyor to provide orientation and rough sequencing of containers arethe same and the oriented and rough sequenced containers in bothembodiments are deposited in a ‘top up’ ‘bottom down’ configuration indrop chute 56 before those rough sequenced containers are deposited oninfeed conveyor 60.

[0132] In either embodiment of the novel orientation conveyor, randomlyoriented containers are deposited in infeed hopper 30 and transported bylaterally disposed elastomeric belts 48 and 50. Each lane 36, 38, 40 and42 includes a separate transposing elastomeric belt 48 and 50 for eachof the plurality of production lines 36-42. Elastomeric belts 48 and 50are disposed between a plurality of pulleys 62 for transporting orientedcontainers from the infeed hopper area 30 to the plurality of dropchutes 56. The oriented containers are continuously moved along theplurality of production lines 36-42 in a continuous operation to providea rough sequencing of containers that are deposited on infeed conveyor60.

[0133] The rough sequencing of the plurality of containers transportedby elastomeric belts 48 and 50 by the plurality of pulleys 62 each ofthe plurality of production lines 36-42 is provided by pliant plates androds in combination with the travel of elastomeric belts 48 and 50 whichare further controlled by a computer which controls each lane through anindividual sensor 64 which is connected through a clutch assembly 68 forcontrolling the speed or stopping each of the plurality of productionlines 36-42 in the event a particular lane needs to be slowed or stoppeddue to a problem further on down along the production line.

[0134] Clutch assembly 68 includes clutch plate 70 and 72 forcontrolling each of the plurality of production lines 36-42 throughorientation conveyor drive shafts 74 and 76 through bevel gears 78 and80 (FIG. 6 and FIG. 8). Bevel gears 78 and 80 on drive shaft 74 providea drive for lanes 36 and 40 through each clutch assembly 68 which mayindividually slow down or shut off production line 36 or 40 in operationwhile drive shaft 76 is connected via beveled gear 82 and 84 to clutchassembly 68 which is connected to production lines 38 and 42 toindividually control or shut down the speed of production line 38 and 42through each of the clutch assemblies 68 similar to those connected todrive shaft 74. Clutch assemblies may also be connected to variablespeed drive assemblies for further increasing or decreasing individuallane speeds in a manner known to those skilled in the art.

[0135] Referring now to FIGS. 4-7 the novel orientation plates andfingers simulating the mechanical action of the hand in orienting thecontainers in accordance with the invention will be further described.The plurality of divider plates 34 separate the plurality of productionlines 36-42 from which the gravity fed randomly oriented containers 14are captured by elastomeric belts 48 and 50 in the area of infeed hopper30. The continuous motion of each of the elastomeric belts 48 and 50 andtheir continuous conveying action eventually removes containers fromhopper 30 even if hopper 30 is filled to capacity. Elastomeric belts 48and 50 in the plurality of lanes 36-42 together with the utilization ofa pivotal plate 86 and 88 which mechanically simulate the action of thehuman hand assist in the orientation and the rough sequencing ofrandomly oriented containers 14 and prevents excess containers fromescaping hopper 30. First pivotal plate 86 is hinged to housing wall 46by pivotal hinge 90 which may include a spring-biasing means. Plate 86is pivotally attached to second pivotal plate 88 through a second hinge92 to allow plates 86 and 88 to resiliently swing and prevent too manycontainers from exiting hopper 30 in a bunched up or unsequencedconfiguration.

[0136] Excess containers are thereby maintained in hopper 30 or can fallthrough the area below hopper 30 in a collection box 94 (FIG. 3) wheretoo many containers are fed into infeed hopper 30 by elevated feedconveyor 22 or where the container strikes elastomeric belts 48 and 50in an angular fashion that allows part of the base 16 (or the topportion 61 in the FIG. 8A embodiment) to fall between elastomeric belt48 and 50. The swinging motion of first pivotal plate 86 in combinationwith the swinging motion of second pivotal plate 88 in reaction to thetravel of elastomeric belts 48 and 50 in exiting infeed hopper 30prevents unoriented bunched up containers from moving out of infeedhopper 30 in a bunched up unoriented configuration.

[0137] Once the oriented containers 53 exit first pivoted plate 86 andsecond pivoted plate 88 they are introduced to a pivoting fingerassembly 94 disposed in each of the plurality of production lines 36-42(FIGS. 5, 6 and 7). The plurality of pivoting fingers 94 simulate theaction of the human fingers in making certain the containers areproperly oriented and assist in the rough sequencing of the containersby contacting first the side, if the container is not properly oriented,and then running over the flat bottom 18 (FIG. 5) to make certain thecontainer is in a substantially perpendicular oriented configuration.The plurality of pivoting fingers 94 are hinged to a bracket 96 througha hinge 98 to allow each of the plurality of pivoting fingers to pivotand assist in the rough sequencing of containers in each of theplurality of production lines 36-42.

[0138] As will be recognized by those skilled in the art the roughsequencing provided by the novel orientation conveyor in the operationof pliant plates and finger in combination with the computer control andmotion of the elastomeric belts can be used for ‘bottom up’ ‘top down’orientation and sequencing or ‘top up’ ‘bottom down‘ orientation. Therough sequencing provided for containers with larger tops than bases caneasily be provided for where such containers have opening 20 and flatbottom are reversed as illustrated in FIG. 8A. However, in the best modeof the invention the ‘bottom up’ ‘top down’ oriented containers aretransported to the plurality of turning plates 54 (drop guides 65 in thealternative embodiment) and deposited through drop chutes 56 in a ‘topup’ ‘bottom down’ oriented configuration on continuous infeed conveyor60. Infeed conveyor 60 is connected to the computer and in the preferredembodiment operates like an accumulation conveyor by providinginformation as to container flow which is used to increase and decreasethe speed of elevator conveyor 22 and control the speeds of theplurality of lanes of the orientation conveyor 32. Infeed conveyor 60then transports and introduces the ‘top up’ ‘bottom down’ oriented androughly sequenced containers 58 to the novel filling and sealingapparatus 100 at one of the screw conveyors 102, 104, 106, 108, 110 and112 (FIG. 11).

[0139] Referring now to FIG. 9 the novel filling and sealing apparatus100 includes three drive motors 114 for driving each set of screwconveyors 102-112 (FIG. 11) which are precisely positioned to turn eachset of two conveyors 102-112 to advance oriented containers 58 along thelength of the screw conveyors to a plurality of inspection, filling andsealing and rejection stations along the length of the novel filling andsealing apparatus 100. The novel filling and sealing apparatus includessupports 116-134 for supporting the novel filling and sealing apparatus100. At the end of each support 116-130 is a cylinder 132 piston 135combination to provide for the precise leveling of the novel filling andsealing apparatus. The piston 134 terminates in a support flange 136that is bolted to a floor via bolt 138. Supports 116, 118, 120 and 122extend from the floor to provide a frame 140 for supporting each productreservoir 142 which is connected by hoses 114 to the individual fillerheads 146. Individual filler heads 146 may be pivoted to a cleaningposition as represented by filler heads 148. The novel filling andsealing apparatus 100 also includes a foil transfer mechanism 150 andsealing mechanism 152 for sealing containers 58 with a foil from each ofa plurality of foil tubes 154.

[0140] Referring now to FIGS. 9, 10 and 11 containers 58 supplied bycontinuous infeed conveyor 60 are introduced to screw conveyors 102-112and are transported in a discontinuous conveyor action along the lengthof the bed 156 of the novel filling and sealing apparatus 100. Forpurposes of illustration the discontinuous operation of positioningscrew conveyors 102-112 will be described with respect to screwconveyors 102 and 104 (FIG. 10) which illustrate the plurality ofstations along the length of the novel filling and sealing apparatus. Inthe novel filling and sealing apparatus in accordance with the best modeof the invention a plurality of independent filling, sealing, inspectionand rejection stations and associated processes are accomplished alongthe length of each of the positioning screw conveyors 102-112.

[0141] As the containers are introduced to the screw conveyors 102-112which, for the purposes of illustration, will be discussed with respectto screw conveyors 102 and 104, the containers are optionally stabilizedby a stabilization cover 97, which is preferably made of clear plasticmaterial such as lexan is supported by a pair of adjustable brackets 99which serve to stabilize containers 38 from wobbling or tipping asillustrated in FIGS. 9, 10 and 10A. The optional stabilization cover 97is generally attached to the infeed conveyor 60 as illustrated in FIG.9. Optional stabilization cover can be eliminated where metal, class orother containers of sufficient mass are filled in the novel filling andsealing apparatus 100. In either application the containers 58 are thenposition sensed by paired fill position sensors 158, 160, 162 and 164.Paired position sensors 158, 160, 162 and 164 determine the positions ofthe containers 58 in both screw conveyor 102 and 104 and provide theinformation to the computer for later use when containers 58 areadvanced by screw conveyors 102 and 104 by motors 114 to the fillposition 166 on both sides of the position screw conveyors.

[0142] If the position sensors 158, 160, 162 and 164 have determinedboth containers 58 are in proper tandem positions on both sides of screwconveyors 102 and 104 and are in fill position 166, then all four of thefiller heads are activated to meter a fluid food product or otherfillable material into the containers 58 in fill position 166 that havebeen advanced to the fill position. In the event the fill positionsensors 158, 160, 162 and 164 do not detect all the containers 58 in theproper tandem or lateral position or that one or both or all of thecontainers are missing, the information supplied by fill positionsensors 158-164 to the computer prevents the release of food materialsor other fluid fillable materials into the one or more missingcontainers 58 in fill position 166. The novel filler and sealingapparatus fills only the containers present in direct perpendicularalignment with filler heads 146 to prevent spillage of unnecessaryrelease of materials through a positive shut-off valve as will bedescribed hereinafter in greater detail.

[0143] For the purposes illustration certain containers have beenomitted between the various work stations. Containers are present inoperation in every space between each of threads of the screw conveyors102 and 104 and in accordance with the invention may be positionedintermediate one or more of the work stations until the spiral conveyoradvances them into one of the work station positions. As illustrated inFIGS. 10, 10A and 12 one or more containers may be disposed on screwconveyors 102-112 at positions between work stations. Containers betweenwork stations are advanced to work stations and filled, sealed,inspected and removed in alternate sets.

[0144] In the preferred embodiment of the invention the novel fillersealer machine has sensors for sensing and providing information to thecomputer as to whether containers are present in their proper tandem andlateral positions. Additionally, the preferred embodiment of theinvention, in addition to having position sensors 158, 160, 162 and 164,also has a fill position 166, a fill inspection position 168, a sealposition 176, a seal inspection position 178 and a single rejectposition 182 that serves to reject all containers 58 that do not passinspection at fill inspection position 168 or pass inspection at sealinspection position 178. These defective containers are all rejectedthrough reject doors 180. In the preferred embodiment containers 58 thatdo not pass fill inspection are not sealed at seal position 176 and arerejected through reject doors 180 without a seal as well as containersthat have been identified as having a defective seal. In operation thepositioning screw conveyors 102 and 104 precisely position a pluralityof containers simultaneously at each of the positions and the conveyorthen stops while operations are performed substantially simultaneouslyat each of the various positions.

[0145] In operation in the preferred embodiment conveyors 102 and 104are stopped and containers 58 are sensed by sensors 158, 160, 162 and164 as another group of containers in the fill position 166 are beingfilled and a second tandem set of containers on each side of conveyors102 and 104 are being inspected in the fill inspection position 168.While in fill inspection position 168 containers being inspected forproper fill may also be inspected for absence of fluids or materials onthe foil seal ridge area 170 on each of the containers 58.

[0146] As fill inspection position 168 containers are being inspectedthe results of the inspection are sent to the computer. In seal position176 containers that have been inspected for proper fill and have passedfill inspection are then purged of the ambient air with a purge gas andfoil seals are moved in perpendicular alignment to the containers inseal position 176 and heat-seal pistons are advanced to seal thecontainers in seal position 176.

[0147] As containers in seal position 176 are being sealed previouslysealed containers in seal inspection position 178 are being inspectedfor proper seal and the results of the inspection are sent to thecomputer. At the same time previously seal-inspected containers as wellas unsealed containers that did not pass fill inspection are abovereject doors 180 in reject position 182. Information from the results ofthe seal inspection and fill inspection are used to open the appropriatereject door 180 below the defective container.

[0148] Once the steps of sensing for the existence of a container inposition, filling containers in place, inspecting containers filled,sealing properly filled containers, inspecting previously sealedcontainers, rejecting containers for improper fill and a bad seal havebeen completed, the positioning screw conveyor again turns to move thecontainers from the idle stations between the work stations to the workstations where once again the containers in fill position 166 are filledwhile filled containers in fill inspection position 168 are beinginspected for fill, properly filled containers in seal position 176 arebeing sealed, containers that were sealed are inspected in sealinspection position 176 and defective containers in the reject position182 are being removed from the production line. This process againstarts over with the turning of the positioning screw conveyor and theadvancement of a new set of containers at work stations. The properlyfilled, sealed and inspected containers are then discharged from outputend 182 of the novel filling sealing apparatus and are transferred fromthe novel filling sealing apparatus 100 onto the accumulation conveyor188. The novel filling sealing apparatus is designed to handle about 600containers a minute along the multiple work areas along the novel screwconveyors 102-112.

[0149] Referring now to FIGS. 10A and 10B an alternative embodiment ofthe invention is illustrated having an optional fill reject position 172and optional fill reject doors 174. The fill reject position 172 isdisposed between fill inspection position 168 and seal position 176 sothat containers displaying fill problems are removed through fill rejectdoors 174 so that only properly filled and inspected containers aretransferred to seal position 176. In the example in FIG. 10A container173 was rejected through door 174 due to an improper fill and is notadvanced to seal position 176. In this embodiment of the invention onlycontainers which fail seal inspection such as container 181 are removedthrough reject doors 180. In this embodiment of the invention as well asin the best mode of the invention only properly filled and sealedcontainers complying with the highest quality control standards aretransported out of the output end 182 of the novel filling sealingapparatus and are transferred from the novel filling and sealingapparatus 100 onto the accumulation conveyor 188.

[0150] The simultaneous filling, sealing, inspection for fill and sealcompliance, optional rejection for improper filling and rejection fordefective fill or seal takes place simultaneously along the length ofconveyors 102 and 104 every time conveyor 102 and 104 are stopped toprovide a full and complete filling, sealing, inspection and rejectionof containers not properly filled or sealed in the novel filling andsealing apparatus of the invention. Once all of the steps of determiningwhether containers are in place, filling containers, inspecting filledcontainers, optionally removing improperly filled containers, sealingproperly filled containers, inspecting seals of sealed containers andremoving containers not meeting inspection standards are completed, thescrew conveyors 102 and 104 turn to advance a new pair of tandemcontainers to sensing positions, filling positions, inspectionpositions, sealing positions and rejection positions to again begin theprocess of filling, sealing, inspection and rejecting containers thathave not been properly filled or sealed in the novel filling and sealingapparatus.

[0151] As will be recognized the simultaneous filling, sealing,inspection and rejecting of containers in the novel filling and sealingapparatus requires precise positional control of the rotationalpositions of each of the screw conveyors 102-112 as the containers aremoved from the continuous infeed conveyor 60 through the screw conveyors102-112 to the output end 184. Not only is the rotational position ofthe screw conveyors 102-112 critical, but also is the substantiallyperpendicular alignment of the containers with each of the inspection,filling, sealing and reject station along the bed 156 of the novelfilling and sealing apparatus. The most critical positional alignmentposition is the containers in seal position 176 which must be positionedin substantially perpendicular alignment to the heat sealing piston towithin one thirty thousandth of an inch tolerance to provide a properheat-seal to the container.

[0152] The critical importance of the rotational position of the screwconveyors 102 and 104at the multiple filling, sealing, inspection andreject stations as well as the perpendicular alignment of the containers58 at each one of the stations is assisted by the utilization of aplurality of guide rails disposed on each side of the screw conveyor102-112. These guide rails 190 together with the action of the screwconveyor and bottom guide rods and seal position plates under sealposition 176 along with a substantially flat bottom surface of thecontainer provides the combination of positive control forces necessaryto provide a positive position control over containers without crushing,bending or binding containers in the novel filling sealing machine ofthe invention.

[0153] Referring now to FIGS. 10, 11 and 14 the guide rails 190 aresupported in place by brackets 192 and 194 together with anchoringbrackets 196. Guide rails 190 are designed to provide minimumresistance, maximum perpendicular alignment for container 58 in screwconveyors 102 and 104. The perpendicular alignment assistance providedby guide rails 190 along with the relationship of the container betweenthe threads 198 and 200 (FIG. 10) of the screw conveyors 102, 104 assistin the perpendicular alignment of container 58 at each of the filling,sealing, inspection and rejection station along the bed 156 of the novelconveyor apparatus 100. In addition a plurality of rods 202 are providedto provide minimal resistance to the flat bottom 18 of container 58 asit moves along conveyors 102 and 104. Rods 202 in the preferredembodiment extend from between the input end (FIG. 11) to the sealposition 176 at which point flat plates or a flat bed extends to rejectdoors 180 to assist in the positive positioning of the container andbalance of control forces utilized to hold the container at closetolerances at the seal position 176 work station. Rods 202 are replacedby flat plates at seal position 176 to assist in providing a flatsupport for flat bottom 18 of container 58 at seal position 176.

[0154] The clockwise rotation of screw conveyors 102 and 104 exertdownward forces on the container on the right side of conveyors 102 and104 from the input end (FIG. 11) and upward forces on the container 58on the left side of screw conveyors 102 and 104. These forces aredissipated and controlled by the utilization of guide rails 190 togetherwith rods 202 and the angular relationship between thread 198 and 200and profile of the container. The control of forces are also assisted bythe materials of which the screw conveyors and guide rails areconstructed. In the preferred embodiment the guide rails are constructedof Teflon® and the screw conveyor is constructed of Delrin® plastic. Inthe preferred embodiment the six screw conveyors are powered by threedrive motors 114, each of which drive motors synchronizes two of the sixscrew conveyors. The screw conveyors are supported by bearings, both atthe ends and the center of each of the screw conveyors. The drive motors114 provide a drive index at a range of 2.4 to 2.5 seconds per cycle perscrew conveyor, producing a range of about 192 containers to 200containers per minute per module, or an output range of about 576containers to 600 containers per minute per all three modules.

[0155] Referring now to FIG. 15 the reject doors are illustrated inwhich both the optional full reject doors 174 and the fill and/or sealreject doors 180 operate in the same manner. For the purposes ofillustration only the reject doors 180 will be described since optionalfill reject doors are configured and operate in the same manner.Containers in tandem are permitted to fall through the four individuallycontrollable and activated doors 180, tow of which doors 180 are oneither side of screw conveyor 102. Each of the doors 180 are pivoted tobed 156 at a pivot 204 and are connected to a pivot bracket 206 and to apiston 208. Piston 208 preferably includes an adjustable mating bracketassembly 210. Mating bracket assembly 210 can be secured by a nut 212 toimpart adjustability between adjustable bracket assembly 210 and piston208. Piston 208 is activated through cylinder 214 which is attached tobracket assembly 216 to open an close reject door 180. As heretoforediscussed, information from fill inspection position 168 and sealinspection position 178 are used to determine whether a particular fillor seal is defective and, if so, once the defective container in thefill inspection position 168 or seal inspection position 178 has beenmoved to reject position 182, the corresponding reject door is opened toremove that container from the screw conveyor 102 production line.

[0156] Referring now to FIGS. 9 and 16 the filling device for fillingcontainers 58 will be further described. Fluid materials such as aflowable food product are pumped from a product supply 151 to a pistoncylinder product reservoir 142 and then are transported through fourhoses 144 by four independently controllable pistons 218 to the fourindependently controllable filler heads 146. The independentlycontrollable pistons 218 are controlled by individual switches 220 formetering the fluid product to filler heads 146 through hoses 144. Fillerheads 146 each contain a further piston 224 with a tapered head 226which fits into a tapered piston seat to form a positive controlshut-off valve 228 for precisely metering flowable materials into fillcontainers 58 in fill position 166.

[0157] Referring now to FIGS. 16A and 16D a modified filler head 141 isillustrated having a positive shut-off valve in accordance with thepreferred embodiment of the invention. The piston 224 and piston seatforming positive shut-off valve 228 of filler head 146 were replaced bya Delrin® nozzle 143 sealed to modified filler head 141 by an O-ringseal 145. Modified filler head 141 also includes an end plate 147 withan air inlet fitting 149. A resilient diaphragm 153 and plenum space 155is provided between end plate 147 and modified filler head 141. A rim157 on nozzle 143 is designed to mate with diaphragm 153 when airpressure is provided through inlet fitting 149 into plenum space 155 toform a positive shut-off valve in accordance with the preferredembodiment of the invention.

[0158] Modified filler head 141 functions as the positive shut-off valveof the preferred embodiment by receiving a fillable product from productsupply 151 through product reservoir 142 by the operation of piston 218to pump the fillable product through product reservoir 142 and hose 144into inlet 161 of modified filler head 141 which fillable product flowsinto chamber 163 around nozzle 143 and past diaphragm 153 and throughpassage 165 into container 58 in fill position 166 (FIG. 10). Once theproper amount of fillable product is metered into container 58 in fillposition 166 air pressure is introduced through an inlet fitting 149 andinto plenum space 155 to force diaphragm 153 down over rim 157 of nozzle143 to close off passage 165 and prevent further product from flowingdown passage 162.

[0159] Referring now to FIGS. 16A, 16B and 16D alternative embodimentsof nozzles 143 are illustrated having a variation of passages 165. Thebody of the nozzles in 16B and 16C are the same as the nozzle in 16Awith a rim 157 and an inlet 167 which in the case of nozzle 169 dividesinto four passages 171 and in the case of nozzle 175 terminates in ninepassages 177. The additional passages 171 and 177 in nozzles 169 and 175are provided to suit the flow viscosities and characteristics of variousflowable products to provide additional control over dripping andsloshing of fillable products during the filling of containers 58 infill position 166.

[0160] Each of the filler heads 146 including modified filler heads 141can be moved from its fill position 166 to a cleaning position asrepresented by filler heads 148 in clean position for cleaning (FIG.17). Referring now to FIG. 17 the cleaning of the novel filling andsealing apparatus will be described for only one of the filler heads 146in the clean position 148 since all the other filler heads are cleanedin the same manner at the same time. Filler head 146 is connected tofilling head cleaning port 230 of cleaner housing 232 and a cleaningsolution from cleaner reservoir 234 is pumped through the outlet 236 ofproduct supply 151 and through piston and cylinder product reservoir142. Product reservoir 142 is connected with a cleaning hose 238 tocleaner housing 232 and through filler head cleaning port 230 intofiller head 146 in cleaning position 148 and through hose 144 back toand through the piston cylinder combination of product reservoir 142.Cleaning solution from cleaner reservoir 234 may be circulated in bothdirections to provide cleaning of the product filler elements. Inaddition the positive shut-off valve 228 may include special cleaningports in filler head cleaning port 230 to assist in the cleaning of thepositive shut-off valve. Modified filler head 141 as well as the variousnozzles 143, 169 and 175 as well as diaphragm 153 and chamber 163 may becleaned in a similar manner. Additional cleaning may be provided for theentire area by cleaning showers to clean all areas exposed to fillmaterials and the foil sealing pistons or other sealing means utilized.The novel ambient air purging foil sealing pistons are mounted to apivotal housing to allow the foil sealing pistons to be pivoted awayfrom the sealing position for cleaning.

[0161] Referring now to FIGS. 18, 18A, 18B, 18C, 18D, 18E and 19 theoperation of sealing mechanism 152 is illustrated together with the foiltransfer mechanism 150 that in the preferred embodiment includes a pickand place mechanism 240 together with a shuttle plate 258. The pick andplace mechanism 240 and shuttle plate 258 coordinate their operationwhen containers 58 are moved into seal position 176 below the novelsealing and purging pistons 242. The pick and place mechanism 240 whichincludes a 130 degree turnable transport mechanism 244 has fourvacuum-activated suction cups 246 that upon the application of a vacuumto each individually controlled suction cup 246 takes an individualcircular foil seal 248 from each of the foil seal supply tubes 250. Asheretofore described, when one or more of the containers 58 are not inseal position 176, a vacuum is not applied to the particular suction cup246 corresponding to the missing container in seal position 176. As aresult, whichever container is missing, the 180 degree turnabletransport mechanism 244 with suction cups 246 does not advance a foilseal 248 to the opening in shuttle plate 258 that corresponds to theparticular seal position 176 missing a container or that has a containerthat has failed fill inspection.

[0162] Once 180 degree turnable transport mechanism 244 receives theprecise number of foil seals 248 needed to seal, containers 58 in sealposition 176, the 180 degree turnable transport mechanism 244 travelsdown cam 252 (FIG. 18) with cam followers 254 and pivots transportmechanism 244 from the suction cup 246 ‘up position’ (FIGS. 18A and 18B)with foils 248 in place to the suction cup 246 ‘down position’ 256 (FIG.18C). At the suction cup ‘down position’ suction cups 246 deposit thenecessary foil seals 248 by the release of vacuum on suction cups 246onto shuttle plate 258 (FIG. 18D)in openings 260.

[0163] Openings 260 containing the requisite foil seals 248 are moved byshuttle plate 258 (FIG. 18D) to above containers 58 in seal position 176(FIG. 20A.) below sealing and purging pistons 242. Just prior to shuttleplate 258 moving foil seals 248 into position above the containers inseal position 176 sealing and purging pistons 242 purge ambient air fromcontainers 58 (FIG. 2G) through a center purge port 262 while transportmechanism 244 returns to its position below seal supply tubes 250 (FIG.18E). Purge port 262 purges ambient air from containers 58 in sealposition 176 with nitrogen gas just prior to the arrival of shuttleplate 258 with foil seals 248. Once shuttle plate 258 is in positionwith foil seals 248, the sealing and purging pistons 242 are advancedtoward containers 58 in seal position 176 which push foil seals 248through openings 260 (FIG. 20A) and crimp foil seals 248 around necks264 of containers 58 in seal position 176 (Picture 3). A comparison ofprior art Picture 2 and 3 with Picture 5 and 6 shows the difference inappearance of the product and foil seal produced in accordance with theinvention utilizing the novel sealing and purging pistons 242.

[0164] Once the foil seals 248 have been pushed through openings 260 andcrimped around neck 264 of containers 58, tapered lip 266 (FIGS. 21C,21D) of sealing and purging pistons 242 assist in pressing foil seal 248in place around the circumference of neck 264 (FIGS. 21A, 21B) andheating element 268 is activated to heat-seal foil seal 248 to lip 270of containers 58. Heating element 268 is spring-biased and is allowed tofree-float within opening 274 of the sealing and purging piston 242. Thefree-floating heating element 268 in opening 274 allows the heatingelement 268 to resiliently conform to the position of containers 58 inseal position 176 to provide a positive seal. Flat plates 203 areutilized in place of rods 202 under seal position 176 to provide a morestable support for bottom 18 of container 53 during sealing of foil seal248. Sealing and purging piston assembly 276 which holds sealing andpurging pistons 242 allows pistons 242 to be pivoted from its positionperpendicular to screw conveyor 102 for cleaning purposes as illustratedin FIG. 21F.

[0165] Referring now to FIGS. 20 and 21 sealing piston 242 includes acylindrical shank 278 which is attached by fastener 280 to the purgingand sealing piston assembly 276. Cylindrical shank 278 includes apassage 282 to provide a purge gas to purge port 262. The fastening ofcylindrical shank 278 in purging and sealing piston assembly 2766 limitsthe movement of cylindrical shank 278 and requires all of the resiliencyin heating element 268 to be borne of the interface between lip 270 ofcontainer 58 and free-floating heating element 268.

[0166] A modified purging and sealing piston 243 is illustrated in FIG.22 in which cylindrical shank 278 is no longer fastened to purging andsealing piston assembly 276 by fastener 280. Instead cylindrical shank278 of purging and sealing piston 243 terminates in a ball or pivotbearing. As illustrated in FIG. 22 the pivot bearing is provided by therounded or tapered end 286 in combination with slightly cupped disk 288which is attached to purging and sealing piston assembly 276 in place offastener 280. It will be recognized the additional pivotability providedby a pivot bearing at the base of the cylindrical shank 278 extends thepivotability of the floating heat element 268. Other types of pivotbearings or ball and socket bearings are illustrated and include atapered rod pivot bearing, FIG. 22A, a Schiele's pivot bearing, FIG. 22Band a ball and socket bearing illustrated in FIG. 22C and FIG. 22D.Other types of pivot or ball bearings may be provided at the end ofcylindrical shank 278 to impart pivotability and provide greaterresiliency in providing a seal on containers 58.

[0167] After containers 58 in seal position 170 are sealed they are thenmoved to seal inspection position 178 for seal inspection (FIG. 10). Theresults of the seal inspection are stored in a computer along with theresults of the fill inspection so that, when the containers are moved toreject position 182, a reject door under the defective container isactivated by the computer to remove the defective container from theassembly line. As a result only containers meeting fill and sealinspection requirements are transported out of output end 184 onto theaccumulation conveyor 188 of the novel production line of the invention.

[0168] As will be recognized by those skilled in the art, the precisepositioning of the container at each of the filling, sealing andinspection stations is critical to provide the simultaneous filling andsealing of containers along the length of screw conveyors 102 and 104.It will also be recognized that the shape of the container in relationto the configuration of screw conveyor 102 is important in positioningand also removing containers through reject doors 180 and also throughoptional fill reject doors 174 where fill reject doors are used. Theadvantage of utilizing fill reject doors is to remove containers fromthe production and not waste resources on handling and possibly sealingcontainers that may not be properly filled or by allowing suchcontainers to remain in the production line. The shape of the containeris important to allow its removal through reject doors 180 since, if thetop portion of the container is larger than the bottom portion of thecontainer, the container will not be able to fall through reject doors180.

[0169] As a result in the best mode of the invention a taperedcylindrical container having a base of a larger diameter and having adecreasing taper to the top is preferred. The preferred taperedcontainer is preferred in the best mode because the container is held inpositive position all along the length of the screw conveyor by not onlythreads 198 and 200 of each of the screw conveyors against the sides ofthe container but also the coaction between the guide rails 190 againstthe side of the container and rods 202 or bottom support plates on thebottom of the container. This positive engagement along the entirelength or the screw conveyor provides the advantages of the invention inprecisely positioning the container at all work stations along thelength of the screw conveyor and allows the close sealing tolerances ofabout one thirty thousandth of an inch to be achieved where thecontainers are sealed with a foil heat-seal.

[0170] The advantages of positive control over the containers along theentire length of the screw conveyor can be a disadvantage in removingcontainers having a larger top from being removed from the screwconveyors since the screw conveyors are not reversed and the tensionupon the sides of the containers is designed to be a positive force tohold the containers in a positive position throughout the length of thescrew conveyors. This positive force on the screw conveyor is providedin the best mode of the invention by utilizing a screw conveyor having auniform diameter from end to end and spiral threads of a uniform spiralangle to uniformly maintain pressure on the container at each of thework stations along the length of each screw conveyor.

[0171] In alternative embodiments of the invention containers having atop larger than the base of the container can be filled and sealed inthe novel filler sealer machine. In such alternative embodiments of theinvention containers having a uniform diameter or a larger top than basecan be filled and sealed in the novel filler sealer apparatus by eitherutilizing a modified screw conveyor or by not removing defectivecontainers from the screw conveyor.

[0172] Referring now to FIGS. 12 and 12A an alternative embodiment ofthe invention is illustrated, where a plurality of containers 300 aresimultaneously filled on both sides of screw conveyor 102 and 104.Containers 300 have a top larger than the bottom of the container andmay be similar in configuration to containers 57 in orientation conveyor32 of FIG. 8A. The simultaneous filling in this case of eight containers300 per conveyor lane coincides with the stopping of the conveyor whilecontainers 302 are simultaneously being sealed while an additional groupof containers 304 are being simultaneously inspected for fill and sealand marked with a dye or ink if the containers did not pass a fillingand sealing inspection. For example, in FIG. 12B container 305 did notpass fill inspection and container 307 did not pass seal inspection andare marked with a dye. Containers 304 not marked and pass inspection,are moved out of the novel filler sealer apparatus and subsequentlypackaged or handled. Containers 305 and 307 that do not pass inspectionand that have been marked with an ink or dye may be subsequently removedat another point in the production line after they exit screw conveyor102 and 104. The embodiment in FIGS. 12 and 12A may be utilized inapplications of the invention where glass or transparent containers arefilled that accommodate sight inspection for fill while the container isbeing inspected for seal.

[0173]FIGS. 13 and 13A illustrate further alternative embodiments of theinvention for providing the simultaneous filling and sealing ofcontainers 300 having a top larger than the base and simultaneouslyremoving defective containers 300 from the screw conveyor utilizing, amodified screw conveyor 301. Modified screw conveyor 301 includesthreads 198 and 200 together with guide rails 190 and rods 202 forpositively engaging containers 58 at positions requiring positivecontrol such as the fill position 166 and seal position 176. Modifiedscrew conveyor 301 includes one or more shaft recessed areas 303extending across one or more work stations that do not require positivecontrol over the container such as fill reject station 172, seal rejectstation 182 or a weigh station 305 (FIG. 13A). Modified screw conveyor301 spans shaft includes a narrow shaft 307 that spans recessed areas303 and interconnects screw conveyor 301 across recessed areas 303 tomaintain positive positioning control over the containers in fillposition 166, seal position 176 and inspection positions 168 and 178.

[0174] Containers 300 having a too of a larger diameter than the base asrepresented by containers A, B, C, D, and E are transported along thelength of modified screw conveyor 301 as in the manner as previouslydescribed except when the containers enter recessed areas 303.Containers first enter shaft recessed area 303 by the action of threads198 and 200 and are advanced by container A pushing container B whichpushes container C which pushes container D which pushes container E.The pushing of container C and D by container B is assisted by a motionvibrator 199 which vibrates the bottom of container C pushing containerC over a reject door such as reject door 174 or reject door 180.Container C and D can be removed from screw conveyor 301 even though thetops are larger than the bottom due to the extra space provided inrecess area 303 due to the reduced circumference of narrow shaft 307.Alternatively a scale 305 (FIG. 13A) could be substituted for doors 180and containers C and D could be weighed since control forces have beenremoved from the sides of the container by threads 198 and 200.

[0175] Referring now to FIG. 13A a further embodiment of a weigh station305 and reject areas is illustrated. The weigh station 305 includes ashuttle plate shaft 321 that operates in unison with shuttle plate 258and depresses button 323 while shuttle plate 258 is supplying foil sealsto sealing and purging pistons 242. The depression of button 323 byshaft 321 raises scale support 325 under each container 300, temporarilyraising the container from out of engagement with threads 198 and 200 toallow an accurate weight to be made of the filled container. The returnof shuttle plate 258 results in the return of shuttle plate shaft 321which retracts scale supports 325 below bed 156.

[0176] Container D (FIG. 13A) and container E (FIG. 13) may be assistedwith partial spiral thread 309 on the end of narrow shaft 307 whichengages container D (FIG. 13A) and E (FIG. 13) when screw conveyor againturns and assists container D (FIG. 13A) and E (FIG. 13) back intothreads 198 and 200 on modified screw conveyor 301. Partial spiralthread 309 may extend partly or entirely across the entire recessed area303 to assist in the movement of containers in recessed area 303. Sincepartial spiral thread 309 is also of a significantly reduced diameterand of a greater spiral angle than threads 198 and 200 sufficient slopin threads exist to allow removal of containers with larger tops as wellas the weighing of containers by the removal of positive control forcesin the recessed areas 303. The constant transfer of energy fromcontainer A to container B to container C to container D to container Ealso assists to continue to advance containers in recessed areas 303. Inthis manner positive control forces are maintained by threads 198 anti200 in areas requiring positive control such as sealing, inspection andfilling areas of modified screw conveyor 301 and positive control forcesare reduced or removed from the containers in recessed areas 303 so thatall types of containers can be weighed and containers with a top ofgreater upper size can be dropped through reject door 174 and 180.

[0177] Referring now to FIGS. 13B and 13C other types of screw conveyorsare illustrated in which the diameter of the screw conveyor varies fromone end to another. As illustrated in FIG. 13B the funnel-shapedconveyor 306 can be utilized to convey containers along the length ofthe conveyor to precise positions for filling, sealing, inspecting andrejecting positions for the containers. In FIG. 13B containers move inthe direction of arrow 315. In FIG. 13C two funnel-shaped conveyors 306are placed in a lateral arrangement to accommodate a rectangular shapedbed 156 of the novel filling and sealing apparatus 100. In theembodiment as illustrated in FIG. 13C the containers can move in thesame direction or in opposite directions where the novel filling andsealing apparatus includes input and output production lines extendingin opposite directions.

[0178] Referring now to FIGS. 24 and 25 the novel filling and sealingapparatus 100 is not limited to filling yogurt containers, fruit juicecontainers or other such containers having a foil seal on the container.As illustrated in FIG. 25 a container 310 that has been filled at afilling position 166 of the novel filling and sealing apparatus istransported to a sealing position 176 where the container may optionallybe purged of ambient air and a rotatable piston 312 terminating in capholder 318 is provided for advancing a screw cap 314 to attach the screwcap 314 onto container 310. The invention may also be utilized for thefilling and crimp-sealing (FIG. 24) of a crimp-sealed container 316 byproviding a cap holder 318 at the end of a pressure piston 319 forapplying a crimp cap 320 to the top of crimp-sealed container 316.

[0179] At this point the filling and sealing is completed on the novelfilling and sealing apparatus having a discontinuous operation of screwconveyors to provide a complete filling, sealing, inspection andoptional container removal operation in a production line providing forthe positioning of containers at multiple work stations along the lengthof the screw conveyors. Once the containers have been filled and sealedand optionally inspected, the filled and sealed container exits thenovel filling and sealing apparatus 100 and is transported in thepreferred embodiment of the invention to an accumulation conveyor 188.

[0180] Referring now to FIGS. 1A, 1B, 26 and 44 the remainder of thenovel production line in accordance with the preferred embodiment of theinvention is illustrated. In the preferred embodiment of the inventiononly properly filled, sealed and fully inspected containers are allowedto continue down the production line, while defective containers havingfilling or sealing defects are removed in the novel filling and sealingapparatus 100. The accumulation conveyor 188 transfers the containers tosleevers 322 and to heat tunnels 324 and finally to novel strawapplicators 326 before the consumer packaged product is placed inshipping cartons as will be described hereinafter in greater detail.

[0181] The accumulation conveyor 188 operates as control station andprovides information to a computer regarding flow rates so that thecomputer with information from accumulation conveyor 188 alone ortogether with infeed conveyor 60 can increase or decrease the speed ofthe elevated feed conveyor 22, the novel orientation conveyor 32 and thespeed of operation of the discontinuous operation of screw conveyors102-112. The accumulation conveyor 188 provides information as to flowrate by utilizing a plurality of conveyor lanes which take the twelvelanes of filled and sealed containers from screw conveyors 102-112 fromthe novel filling and sealing apparatus and restrict the twelve lanesdown to nine forward lanes in the accumulation conveyor 183.

[0182] The two outside lanes 328 and center lane 330 (FIG. 27) do notflow the entire length of the accumulation conveyor 188. Instead halfway through the accumulation conveyor 188 the two outside lanes 328 andthe center lane 330 are divided by dividers 332, 334 and 336. Divides332, 334 and 336 allow outside lanes 338 and center lane 330 tocontinuously operate in a reverse direction as represented by arrows342. The operation of outside lanes 338 and center lane 3330 in anopposite direction allows bunched up containers to be diverted back ontothe reverse flowing conveyor lanes 338 and 330 and not proceed furtheron through the production line into the remaining three production lines344, 346 and 348.

[0183] The operation of the reverse flowing conveyor lanes provided byoutside lanes 338 and center lane 330 operates much in the way of acounterflow mechanism for fluids in which excess containers are movedoff the three direct conveyor lanes 344, 346 and 348 and caught in areverse flow or eddy current where the containers are constantly movingso as to not plug up the main production lines 344, 346 and 348 andremain in circulation without entering the production line until suchtime as the containers are able to be directly channeled onto the directproduction lines 344, 346 or 348.

[0184] Drive for the accumulation conveyor is provided by drive motors350 which are connected to an accumulation disconnect panel 352 disposedon wall 354. Also disposed on wall 354 is a control panel 356 and powerpanels 358 for the heat tunnel 324.

[0185] The information as to flow rate and backflow information issupplied to a computer 340. Computer 340 can adjust the flow rate toreduce the accumulation of containers on the accumulation conveyor byslowing down the elevated feed conveyor 22, the novel orientationconveyor 32 or the novel filling and sealing apparatus 100 to adjust therate of production of the novel production line. The accumulationconveyor 188 in addition to providing information to computer 340 forincreasing and decreasing the rate of production also regulatesproduction flow for when any of the screw conveyors 102-112 need to beshut down or when one of the lanes of the plurality of lanes of thenovel orientation conveyor have to be shut down or when one or more ofthe direct production lines 344, 34 b and 348 need to be shut down inthe event one of the sleevers 322, ovens 324 or straw applicators 326 isoff line or requires maintenance. In the event one of the three directproduction lines 344, 346 or 348 require a diversion of the filled andsealed containers to other production lines, the accumulation conveyorprovides for the diversion of the filled and sealed containers to theother remaining production lines as will be described hereinafter ingreater detail.

[0186] Referring now to FIGS. 26 and 28 the accumulation conveyor 188together with computer 340 controls production by diverting productionto other lanes by shutting down individual lanes where, for example, asleever 322 or oven 324 or novel straw applicator 326 runs out of strawsin line 348 by swinging divider 360 across outside lane 328 to diverter362. This diverts all production from production line 348 to theremaining two production lines 344 and 346. Divider 360 is pivotallyattached to frame 364 at pivot 366 to close down line 348. When lanesare shut down the novel computer controlled production line processesthe information and can then slow down elevated feed conveyor 22, novelorientation conveyor 32 as well as slowing down or stopping productionfrom one of the screw conveyors 102-112 of the novel filling and sealingapparatus 100.

[0187] Accumulation conveyor 188 can shut down center production line346 and divert filled and sealed containers to the remaining productionline 344 and 348 by pivoting divider 368 across the center lanes tocontact diverter 362 (FIG. 29). Once divider 368 is in contact withdiverter 362 all remaining production flows down open production lines344 and 348 or is channeled through the back flow outside lanes 338.Similarly the accumulation conveyor 188 can close off production line344 (FIG. 30) and channel all production to production lines 346 and 348by pivoting divider 370 to divider 334 to shut down production line 344.Divider 370 like divider 360 is pivoted to frame 364 by a pivot 372.

[0188] Once the filled and sealed containers exit accumulation conveyor188 the containers in accordance with the preferred embodiment of theinvention are then sleeved in sleevers 322 to apply labels or sleeveswith labels to the outside of the filled and sealed containers. Thesleevers which apply labels to the containers may be any type of priorart sleever or labeler currently on the market to apply labels orsleeves which are connected to the novel production line throughcomputer control and related computer program to control the operationof the entire novel production line. In the preferred embodiment of theinvention sleevers 322 are American Fuji Seal, Inc. sleevers and may beobtained prom American Fuji Seal, Inc. of Fairfield, N.J. 07004 and as aresult will not be described in further detail.

[0189] In addition to the attaching of a sleeve with a label in thenovel production line a heat tunnel 324 which can be a steam or radiantheat tunnel and preferably is a steam tunnel which is provided toshrink-wrap the plastic sleeve containing the label to the packaged andsealed container. The heat tunnels for heat-sealing the sleevecontaining the label to the container can also be obtained from AmericanFuji Seal of Fairfield, N.J. 07004 arid as a result will not bedescribed in further detail. Once the sleeve containing the label isshrunk to the containers the containers are transported down productionlines 344,346 and 348 to the novel straw applicators 326 for attachingan individually wrapped straw to the outside of the filled and sealedcontainer.

[0190] Referring now to FIGS. 31, 31A, 32, 32A, 33 and 33A, one of thenovel straw applicators 326 is illustrated. Straw applicators 326 mayoperate as stand alone units for advancing individually wrapped strawson demand or be linked to the computer for controlling the entireproduction line. As heretofore described each production line 344, 346and 348 includes a novel straw applicator 326, each of which appliesstraws to filled and sealed containers coring down one of the productionlines 344, 346 or 348. For purposes of illustration only one of thenovel straw applicators 326 associated with line 346 will be describedsince the other straw applicators operate the same for lines 344 and348.

[0191] As a filled and sealed and labeled container 58 moves downproduction line 346, the filled, sealed and labeled container 58 issensed by sensor 380 which may be attached to the straw and tape supplyhousing 382. Straw and tape supply housing 382 houses a plurality ofindividually wrapped telescoping straws 384 which are interconnected bya plastic band 386. Straw and tape housing also houses a roll ofadhesive tape 388. Straw plastic band 386 is advanced past straw webpivot bar 387 while adhesive tape 388 is advanced past adhesive tape webpivot bar 389. A bonding roller 391 bonds adhesive tape 388 to the strawplastic band 386. As soon as sensor 380 senses the presence of a filled,sealed and labeled container 58 on production line 346 the drive motor390 is engaged to sequence the delivery of an individually wrappedtelescoping straw to container 58 as it contacts straw applicatorcylinder 392 as will be described hereinafter in greater detail.

[0192] The timed relationship in the preferred embodiment is provided bya demand sensor 380 which activates and controls the operation of drivemotor 390. Individually wrapped telescoping straws 384 on plastic band386 and adhesive tape 388 are drawn out of housing 382 by drive motor390 which is connected to drive shaft 394 (FIG. 32A) through bearing 396connected to frame 398. Drive shaft 394 is connected to pulleys 400 and402 for driving divided straw conveyor belts 404 and 406. Divided strawconveyor belts 404 and 406 are divided into upper straw conveyor belt404 and lower straw conveyor belt 406 that connects drive pulley 400with notched pulley 408. Similarly drive pulley 402 connects lower strawbelt 406 with notched pulley 408. Notched pulley 408 includes aplurality of notches 410 which accommodate the individually wrappedtelescoping straws 384 and positively engage and control the positioningof the telescoping straws 384 into the notches 412 on upper strawconveyor belt 404 and lower straw conveyor belt 406. Notched pulley 408is journalled to frame 398 through a bushing 414. The notches 410 innotched pulley 408 together with notches 412 in upper straw conveyorbelt 404 and lower straw conveyor belt 406 provide a positive engagementand advancement of the plastic band 386 connecting the individuallywrapped telescoping straws 384.

[0193] Laterally disposed to notched pulley 408 and drive pulleys 400and 402 is conveyor belt 416 connected between two servant pulleys 418and 420 (FIG. 31A). Servant pulleys 418 and 420 together with conveyorbelt 416 provide an abutting surface to upper straw conveyor belt 404and lower straw conveyor belt 406 to capture, engage and positivelyadvance telescoping straws 384 between straw conveyor belts 404 and 406and conveyor belt 416. Servant pulley 418 draws an adhesive tape 388from housing 382 and applies the adhesive tape 388 to the flat side 422along the back of the plastic band 386 of the individually telescopingstraws 384. As soon as the adhesive is applied to the flat side 422 ofindividually wrapped telescoping straws 384, the protective layer 424 ofthe double-sided adhesive tape 388 is removed and the protective layer424 is discarded as the straw bearing the adhesive backing on theindividually wrapped telescoping straws 422 proceeds down between upperstraw conveyor belt 404, lower straw conveyor belt 406 and conveyor belt416.

[0194] To further assist in the positive alignment and engagement of thestraws between notched pulley 408 and servant pulley 418, a strawtensioning mechanism is provided in straw and tape housing 382. Thestraw tensioning mechanism (FIGS. 35 and 36) includes a notchedtensioning pulley 426 which, like notched pulley 408, includes aplurality of notches 428 which match the contour of the telescopingstraws 384 and serve to tension plastic band 386 and assist in thetensioning, sequencing and feeding of the individually wrappedtelescoping straws to notched pulley 408 and upper straw conveyor belt404 and lower straw conveyor belt 406. A roller pulley 430 assists inthe removal of the layered telescoping straws 432 in housing 382.Notched tensioning pulley 426 cooperates with feed cylinders 434 and 436in sequencing and tensioning and feeding the straws to notched pulley408 and the upper and lower straw conveyor belts 404 and 406.

[0195] Referring now to FIGS. 31A, 32A, 33A: and 34 the means forseparating the individually wrapped telescoping straws 384 from theplastic band 386 is illustrated. The means for separating theindividually wrapped telescoping straws 384 with the adhesive applied tothe flat side is disposed intermediate drive pulleys 400, 402 andnotched pulley 408 (FIG. 32A). In the best mode of the invention themeans for separating the individually wrapped telescoping straws 384 isa knife assembly 438 which includes a knife blade 440, preferably havinga serrated cutting edge 442 (FIG. 33A). The serrated edge 442 of knifeblade 440 is generally in the retracted position as illustrated in FIG.34 until the plastic band 386 between individually wrapped telescopingstraws 384 is in position at which time solenoid 444 activates piston446 to advance the knife blade past the protective mechanical sheath 448to result in serrated edge 442 cutting the plastic band 386 asillustrated in FIG. 33A.

[0196] Mechanical sheath 448 includes a pair of laterally disposedsupport cylinders 450 and 452 as well as associated springs 454 tomaintain mechanical sheath 448 in its protected covering position asillustrated in FIG. 34. The action of solenoid 444 in advancing piston446 causes the knife supporting assembly 456 to bias springs 454 andadvance the serrated edge 442 of knife blade 440 to cut the plastic band386 of the individually wrapped telescoping straws 384. Thereafter theindividually wrapped telescoping straws continue their advancementtoward drive pulley 400 and 402. When the individually wrappedtelescoping straws with an adhesive back, serrated by the knife assembly438, reach drive pulleys 400 and 402 they are transferred onto a novelstraw application belt 460.

[0197] Referring now to FIGS. 31A, 32A, 37, 38, 39 and 40 theelastomeric novel straw application belt 460 results in the transfer ofthe separated individually wrapped telescoping straws with an adhesiveback from upper straw conveyor belt 404 and lower straw conveyor belt406 onto elastomeric straw applicator belt 460. Elastomeric strawapplication belt 460 is disposed between upper straw conveyor belt 404and lower straw conveyor belt 406 and is driven by drive shaft 394 insynchronization with straw conveyor belts 404 and 406. The transfer ofthe individually wrapped telescoping straws 384 onto the elastomericstraw application belt 460 results in the advancement of the capturedelastomeric straw in the notched straw receiving pocket 462 and theiradvancement toward the straw applicator cylinder 392.

[0198] Elastomeric straw application belt 460 is precisely controlled bydrive pulley 464 on drive shaft 394. Elastomeric belt extends from drivepulley 464 to straw applicator cylinder 392 and back to drive pulley 464through idler adjustment pulley 466. The precise transportation ofindividually wrapped telescoping straws 384 in elastomeric belt 460 iscontrolled through the use of laterally adjacent timing notches 468 onthe back side of elastomeric straw application belt 460 together withrubber bands 480, 482 extending from drive pulley 464 to servant shaft484 journalled to housing 398 through bearing assembly 486. Servantshaft 484 includes grooves 488 for capturing rubber bands 480 and 482 inrotational alignment with drive pulley 464. The combination of rubberbands 430, 482 with notched receiving pockets 462 holds individuallywrapped telescoping straws in notched receiving pockets until a vacuumis applied to notched receiving pockets 462 in elastomeric strawapplication belt 460.

[0199] The maintenance of the separated individually wrapped telescopingstraws 384 are further maintained in notched straw receiving pockets 462by the application of a vacuum through a plurality of ports 470extending through elastomeric straw application belt which connect thenotched straw receiving pockets to a vacuum supply box 472. The vacuumsupply box 472 runs along the back side of elastomeric straw applicationbelt 460 to apply a vacuum to maintain the separated individuallywrapped telescoping straws 384 with an adhesive on the back until thestraws reach the straw applicator cylinder 392 at which point theadhesive back flat surface of the adhesive coated straw contacts sleevedcontainer 58 to apply the straw to the side of the container as ittravels down production line 346.

[0200] As previously discussed the novel continuous production line ofthe invention integrates the continuously operating elevated conveyor 22with the continuously operating novel orientation conveyor 32 with thecontinuously operating infeed conveyor 60 with the discontinuousoperation of screw conveyors 102-112 in the novel filling and sealingapparatus 100. The discontinuous operation of screw conveyors 102-112are integrated with the continuously operating accumulation conveyor188, the continuously operating sleeves 322 and the continuouslyoperating heat tunnels 324 with the discontinuously operating strawapplicators 326 which operates only on demand to advance straws andattach straws when one of the three production lines 344-348 provide afilled, sealed and sleeved container 58.

[0201] The integration of the continuous and discontinuous productionlines to provide a final packaged product is achieved through theutilization of a computer control system for controlling the entireproduction operation for the filling, sealing and labeling andcompletion of the final filled, sealed, labeled end product with a strawapplied to it. The operation and control of the integrated productionline will be further described with respect to FIGS. 41A-41G whichillustrate a computer flow char logic for operating the novel fillingand sealing machine of the novel production line.

[0202] Referring now to FIGS. 41A-41F and 42 the time operation sequenceand operation of the novel filling and sealing machine in the novelintegrated production line is illustrated. The novel filling and sealingmachine is activated by turning the power on as represented by block 474which starts the process by initializing the programmable logic controland the servo-control as represented by block 476. The position screwconveyors 102-112 are set in the home position as represented by block478. Once the screw conveyors 102-112 are in the start or home positionthe various functions of the machine and lane options are selected forvarious production lines are entered as represented by block 500. Thisresults in a number of procedures which check various stages of theproduction line including a determination as to whether the pick andplace mechanism for the 180 degrees turnable transport mechanism 244 isin position as represented by block 504 as well as various fill sensorsand fill sequencers are in position with valves closed, pistonsretracted and the positive shut-off valve activated as represented bythe logic circuits and related interrogation blocks 506 and 508 beforethe machine is ready for operation as represented by sequence block 510.

[0203] Once the machine is ready for operation, various logic loops areperformed as represented by logic blocks 512, 514, 516 and 518 beforethe position screw is activated and determination is made whether thepaired position sensors 158-164 have sensed the presence of a containerat the screw conveyor apparatus as represented by block 517 and whichthen proceeds to the fill operation as represented by block 521. Thecomputer program prepares for the filling of the containers afterdetermining whether a container is present as represented by block 519before proceeding to open the positive shut-off valve, as represented byblock 520, resulting in the extending of pistons to transfer the product(block 522), the closing of the positive shut-off valve when the limitswitch is contacted (block 524), then opening the supply inlet valve(block 526), retracting the product piston (block 528) and closing thesupply inlet valve (block 530), when the retract limit switch iscontacted as illustrated in FIG. 41C.

[0204] Meanwhile the pick and place logic loop, as represented by block532, is initialized and the logic sequence of determining whether acontainer is present at the heat-seal staging area (block 540) isaccomplished which includes activating vacuum to move foil to theshuttle plate and then releasing vacuum to transfer foil to the shuttleplate (block 542) and determining whether the shuttle plate is under theheating heads (block 544) before the heater heads are moved down to sealthe container (block 546) as illustrated in FIG. 41D. Simultaneouslywith the filling, the reject circuit as represented by block 534 isactivated for simultaneously determining whether to reject the containerdue to improper fill through a reject door as represented by block 536(FIG. 41E) or whether to reject the container due to a missing foil seal(block 538) or due to a bad seal (block 540). If either the container 58either failed seal inspection, does not have a seal or the seal isdefective or has been improperly filled reject door 180 is opened asrepresented by block 544 in FIG. 41E.

[0205]FIG. 41F illustrates the automated operation of the clean in placedevice for providing periodic cleaning of the novel filling sealingmachine of the invention. The clean in place operation is initiated byopening the positive shut-off valve in filler head 146 by retractingpiston 224 from positive shut-off valve 228 as represented by block 550.Once the positive shut-off valve is opened the cleaning supply inletvalve is opened (block 552) the timing of the cleaning cycle isinitiated (block 554). At the completion of the cleaning cycle thesupply inlet valve is closed (block 556), the positive shut-off valve isclosed (block 558) and the filler head is replaced to the fill positionas represented by block 560 in FIG. 41F. The positive shut-off valve 228provided by diaphragm 153 and rim 157 is similarly opened in modifiedfiller head 141 by the removal of air pressure from plenum space 155 toprovide for cleaning in the same manner as with filler head 146.

[0206] Additional computer program and control is provided for the novelproduction line of the preferred embodiment including the operation ofthe elevator conveyor, operation of the rough sequencing orientationconveyor, operation of the accumulation conveyor, operation of theconveyors for the sleevers and heat tunnels as well as for the operationof the novel straw applicator apparatus to provide a continuousproduction line to maintain an integrated production over variouscontinuous and discontinuous conveyor processes, number of productionlines and speeds of production throughout the novel conveyor productionof the invention as illustrated in FIG. 43A, FIG. 43B and FIG. 43C. Thepower is turned on as represented by block 580 which starts the processby initiating the programmable logic control and initiating the servocontrols as represented by block 582. The machine functions and laneoptions are selected as represented by block 584.

[0207] The logic loop for integrating the novel integrated automatedproduction line includes control of the orientation conveyor 32 by firstdetermining the amount of containers on infeed conveyor 60. If any laneof the infeed conveyor is about 75% or less full the clutch assembly 68is engaged to run orientation conveyor 32 as represented by blocks 586,588 and 590. In the event any lane of the infeed conveyor 60 is greaterthan about 75% full then clutch assembly 68 is disengaged as representedby blocks 588 and 592 to slow down input to one or more of the screwconveyors 102-112 of the novel filling and sealing machine 100 asillustrated in FIG. 43A.

[0208] The logic loop for regulating the operation of the novel fillersealer machine 100, the sleever 322 and heat tunnels and productionlines 344, 346 and 348 by accumulation conveyor 188 is illustrated inFIGS. 43B and 43C. As illustrated by blocks 594 and 5966 the amount offilled containers 58 on the accumulation conveyor control theoperational speed of the novel filler sealer machine which for purposesof illustration are run at 30%, 50% and 100% production rates asillustrated by blocks 598, 600 and 602 respectively. The speed ofoperation of sleevers 322 and ovens 324 are similarly regulated by aHartness infeed conveyor 603 (FIG. 44) available from HartnessInternational of Greenville, S.C. (block 604 and 606) which likeaccumulation conveyor 188 controls the speed of operation of thesleevers 322 and ovens 324 in lanes 344, 346 and 348 which for purposesof illustration are run at 25%, 50% and 100% as illustrated by blocks608, 610 and 612 of FIG. 43B.

[0209] Referring now to FIG. 43C tae computer control of the productionline can also include control of the packing of cartons containing thefilled, sealed and packaged consumer product with the straw applied tothe outside of the container by including control of the palletizerinfeed conveyor (block 614) which controls the rate of production by theHartness case packer as represented by block 616 and 618. The palletizerinfeed conveyor is a commercially available conveyor obtained from FANUCRobotics of Irvine, Calif. The palletizer infeed conveyor like theaccumulation conveyor provides information to the computer to controlthe boxing of filled, sealed and inspected containers. The Hartness casepacker 620 (FIG. 44) is a carton packaging machine also available fromHartness, International.

[0210] The input elevated conveyor provides a single continuousproduction line which is divided into four separate production linesthat are susceptible to individual control and which provides for theorientation and rough sequencing of containers that are then fed intothe four production lines of the novel sealing and filling apparatus100. The novel production line also includes provision for shutting downone or more of the production lines in the event there is a jam or faultin any of the lines, without stopping the entire production operation.The four production lines from each of multiple work stations of thenovel filling and sealing apparatus of the invention. The novel fillingand sealing apparatus of the invention utilizing the positioning screwconveyor receives and indexes the containers from the orientation deviceand transports those containers to the plurality of work stations in aplurality of production lines along the novel filling and sealingapparatus of the invention.

[0211] The novel filling and sealing apparatus fills pairs of containersto a six ounce fluid capacity with an acceptable overflow of about ⅛ ofan ounce without sloshing or spilling the containers during production.Further the novel filling and sealing apparatus handles a plurality ofcontainers at various stations to inspect, seal, remove and purgeambient air from the containers and provide an aesthetically pleasingcrimp on the foiled lid with a tab folded (and not creased) up and overto lie on the top of the container. All containers not meeting theacceptable product content level or all containers not properly sealedare rejected through doors at the bottom of the bed of the novel fillerand sealer apparatus of the invention.

[0212] The frame assembly of the novel filler and sealer apparatus ismade of stainless steel with sliding access doors made of ⅜ of an inchclear Lexan® plastic to provide for an ease of cleaning as well asmaintaining a clean production environment. The sliding access doorsinclude a safety interlock feature to prevent access to the machineduring operation. The product filler assembly includes sensors that notonly detect the presence of containers but also whether the containershave been properly filled as well as an electronic feed-back adjustmentsystem by which the volume of dispensed food product is controlled bythe stroke of the piston to prevent multiple containers from beingimproperly filled. The filling system is activated by opening the fillermanifold actuator and retracting the filler cylinder which draws in theproduct. The filler manifold actuator is then closed, the fillercylinder pushes forward and simultaneously the positive shut-off valveopens, pumping the product into the container. The positive shut-offvalve then closes to prevent any product from dripping during thefilling cycle. In the event a container has a low product fill thesensor will also signal the programmable logic control and thatcontainer is then rejected from the novel filling and sealing productionline and this information is then used to modify the time the positivecontrol valve remains open to automatically correct for fill errors foreach of the filler heads.

[0213] The pick and place assembly in the preferred embodiment utilizeseight vacuum cups four vacuum cups per each position screw conveyor witheach pick and place assembly accommodating two position screw conveyors.As a result three pick and place mechanisms are mounted oncross-supports to accommodate the twelve production lanes provided bythe six position screw conveyors. The vacuum cups of the pick and placemechanism are operated individually by pumps and valves to individuallyand selectively remove foils located above the assembly and then allowthe pick and place mechanism to mechanically pivot 180 degrees by guideshafts and cams driven place mechanism are operated individually bypumps and valves to individually and selectively remove toils locatedabove the assembly and then allow the pick and place mechanism tomechanically pivot 180 degrees by guide shafts and cams driven bycylinders so that at the bottom of the stroke the pick and placemechanism deposits the foil directly down into a single shuttle platehaving twenty-four cavities for accommodating the twelve productionlanes provided by the six position screw conveyors. If any container hasbeen removed or is defective, the foil is not removed and thecorresponding opening for the shuttle plate remains empty.

[0214] The shuttle plate then moves from the pick and place assemblyposition to the heat-seal position to line up the fill seal in directperpendicular alignment to the heat-seal pistons. However, prior to theadvancement of the shuttle plate assembly the heat-seal pistons purgethe filled containers with nitrogen gas through a manifold operated bythree solenoid control valves. The nitrogen is routed, through thepistons' heads as previously described, and when all of the containersthat are to be sealed are purged with nitrogen gas, the shuttle platemoves into position and the pistons are advanced through the openings inthe shuttle plate to seal the foil to the container to provide a filledand sealed container.

[0215] As the foil is heat-sealed to the container it is alsoform-fitted around the top surface of the container (Picture 5 and 6)and a foiled tab provided on the foil seal protrudes outwardly and, asthe shuttle plate moves back to the pick and place position, it foldsthe tab over the top of the container. As the container exits thesealing area the tab is brushed back to bend the tab over the top ofcontainer to provide a final filled and sealed container. Any containernot properly having a proper foil seal or with low product level arerejected as previously described.

[0216] The filled, sealed and inspected containers are then sleeved witha sleeve containing a label and the sleeve is heat-shrunk to thecontainer in the heat tunnels. A telescoping straw is applied to theoutside of the container with the novel straw applicator to provide afinal, filled, sealed, labeled, packaged product including a telescopingstraw as illustrated in Picture 4. A comparison of Picture 4 withPicture 1 (prior art) illustrates the difference in appearance of thefinal product as a result of utilizing the novel straw applicator aswell as the utilization of the novel ambient air purging heat-sealingpistons to form fit the foil seal around the container in the novelfiller sealer machine of the invention.

[0217] The novel filling and sealing machine is controlled by an AllenBradley SLC 5/04 PLC. A programmable logic control monitors all of thesensors discussed in addition to failsafe sensors located on all majorassemblies. The novel production line can include screens and computerinterfaces for operators to monitor the entire automated productionsystem.

[0218] The cleaning of the novel filling and sealing apparatus isprovided by a clean in place showering system which utilizes a series ofoverhead clean in place tubing which creates a sanitized water showersystem for cleaning all of the components which handle food orcomponents upon which food product can be spilled during production. Thenozzles of the showering system create an overlapping fan-like dowsingeffect for dowsing all of the lanes in the novel filling and sealingmachine. The clean in place system further circulates cleaning solutionthrough the filler manifolds, filler valves to the filler pumps and tothe positive shut-off valves and then returns the cleaning solution tothe clean in place manifold. The closed loop clean in place systemrequires that all internal components are free from cracks and otherimperfections or welds that would prevent proper cleaning during theclean in place cycle. The same is true with the heater heads which aredesigned to pivot toward the output end of the novel filling and sealingapparatus of the invention. The pivotable heater heads allows access forcleaning of any heater heads that might contact any food productsurface.

[0219] As will be recognized by those skilled in the art the novelintegrated automated production line can be used to fill containersother than yogurt beverage containers or other yogurt product containersand is applicable to various types of fluid food products, particularlybaby food, dairy products, creams, puddings and food as well as tofilling containers with non-food fluid materials in a liquid or dryform. As will be further recognized by those skilled in the art thenovel production line is not limited to plastic containers but can beeasily adapted to glass bottles, metal or other containers which may ormay not be transparent and from which the level of the liquid can beread either through the container or sensed by a sensor through the topof the container to determine the volume of material in the container orweighed in novel filler sealer apparatus where the contents of thecontainer are sold by weight.

[0220] It will also be appreciated the invention is not limited tocontainers that have a top of a cross-section less than the base of thecontainer since such containers can be filled in alternative embodimentsof the novel filling and sealing machine of the invention. It will befurther appreciated that various portions of the novel production lineare novel in their own right including the orientation conveyor, novelfilling and sealing apparatus and novel straw applicator which may beused alone in various other types of production lines without using theentire novel production line of the invention. Similarly certain aspectsof the production line, including the novel ambient air purging sealerpiston, positive shut-off valve, novel straw applicator belt and novelscrew conveyor, novel retractable production line scale may be utilizedwithout utilizing the entire production line, entire machines or entirenovel systems of the present invention. These subcomponents as well asthe entire novel production line are each themselves subject to changesand modifications by those skilled in the art for purposes ofimplementing the invention in a variety of applications. In addition thecomputer control of production flow techniques utilizing theaccumulation conveyor(s) may be achieved by other flow rate mechanismsalone or with conveyors and such flow rate control mechanisms will bereferred to generically as “accumulation means”. As a result thoseskilled in the art will recognize the invention has a wide range ofapplications and implementations which are deemed included within thescope of the present invention as defined in the following claims.

[0221] Further, as used herein and in the following claims the word‘comprising’ or ‘comprises’ is used in its American technical sense tomean the enumerated elements include but do not exclude additionalelements which may or may not be specifically included in the dependentclaims. It will be understood such additions, whether or not included independent claims, are modifications that both can be made within thescope of the invention. It will be appreciated that these and othermodifications can be made within the scope of the invention as definedin the following claims.

1-118. (Canceled).
 119. An orientation conveyor apparatus for orientingand sequencing containers comprising: (a) a plurality of container lanesin which each container lane is separately driven by two elastomericbelts supported by pulleys and driven by gears; (b) an infeed hopper atthe first end of said plurality of container lanes and interconnectingsaid plurality of container lanes at said first end; (c) a funnel-shapedhousing disposed above each of said plurality of container lanes; (d) aplurality of spring-biased pliant plates pivotally disposed intermediatesaid funnel-shaped housing and said plurality of container lanes; and(e) a drop chute disposed at each end of said, plurality of containerlanes.
 120. The orientation conveyor apparatus for orienting andsequencing containers of claim 119 further comprising a plurality ofturning plates disposed intermediate said plurality of spring-biasedpliant plates and said drop chute.
 121. The orientation conveyorapparatus for orienting and sequencing containers of claim 120 furthercomprising means for increasing and decreasing the speed of each lane ofsaid plurality of container lanes.
 122. The orientation conveyorapparatus for orienting and sequencing containers of claim 121 furthercomprising a clutch for disengaging each lane of said plurality ofcontainer lanes.
 123. The orientation conveyor apparatus for orientingand sequencing containers of claim 122 further comprising computercontrol of said clutch and said means for increasing a and decreasingthe speed of each lane of said plurality of container lanes.
 124. Theorientation conveyor apparatus for orienting and sequencing containersof claim 119 wherein every two lanes are interconnected by gears. 125.The orientation conveyor apparatus for orienting and sequencingcontainers of claim 123 further comprising a plurality of pivotable rodsdisposed intermediate said funnel shaped housing and said plurality ofcontainer lanes.
 126. The orientation conveyor apparatus for orientingand sequencing containers of claim 119 further comprising a conveyorelevator for depositing containers in said infeed hopper.
 127. Theorientation conveyor apparatus for orienting and sequencing containersof claim 126 further comprising a plurality of scraper plates forremoving excess containers from said conveyor elevator.
 128. Theorientation conveyor apparatus for orienting and sequencing containersof claim 119 wherein each of said plurality of spring-biased pliantplates include a second plate spring-biased to each of saidspring-biased pliant places.
 129. The orientation conveyor apparatus fororienting and sequencing containers of claim 119 further comprising aplurality of drop guide plates disposed intermediate said plurality ofspring-biased pliant plates and said drop chute.
 130. A heated pistonfor heat-sealing a foil to a container comprising: (a) a pivotableassembly for housing a plurality of pistons; (b) a plurality of pistonshaving a first end and a second end disposed in said pivotable assembly;(c) a plurality of heating elements spring-biased to said first end ofsaid piston; and (d) a plurality of gas purge ports disposed in saidfirst end of said plurality of pistons.
 131. The heated piston apparatusof claim 130 further comprising a plurality of pivot joint attachmentsfor attaching each of said second end of said plurality of pistons tosaid pivotable assembly.
 132. The heated piston apparatus of claim 131further comprising a plurality of cup-shaped elements intermediate saidpivot joint attachments and said pivotable assembly.
 133. The heatedpiston apparatus of claim 130 wherein said first end of each of saidplurality of pistons terminates in a flange surrounding saidspring-biased heating elements.
 134. A piston for heat-sealing a foilcomprising: (a) a cylindrical shaft having a first end and a second end;(b) a spring-biased heating element connected to said first end; (c) agas purge port connected to said second end of said cylindrical shaft;and (d) a channel through said cylindrical shaft connecting said gaspurge port through said cylindrical shaft.
 135. The piston for sealing afoil of claim 134 further comprising a pivot joint attachment at saidsecond end of said cylindrical shaft.
 136. The piston for sealing a foilof claim 135 wherein said first end of said cylinder terminates in aflange surrounding said spring-biased heating element.
 137. The pistonfor sealing a foil of claim 136 wherein said flange is tapered.
 138. Thepiston for sealing a foil of claim 134 further comprising a ball jointattachment at said second end of said cylindrical shaft.
 139. The pistonfor sealing a foil of claim 135 further comprising a cup-shapedspring-biased element for receiving said pivot joint attachment.
 140. Astraw applicator apparatus comprising: (a) a first conveyor beltdisposed between a first and a second pulley: (b) a second conveyor beltdisposed between a third and fourth pulley, said second conveyor beltabutting a portion of said first conveyor belt; (c) a third conveyorbelt extending from the terminus of said first conveyor belt and saidsecond conveyor belt to an applicator pulley, said third conveyor belthaving on one side notches for receiving straws and on the other sidevacuum ports communicating with said notches through said third conveyorbelt; and (d) a vacuum chamber for providing a vacuum to a portion ofsaid third conveyor between said terminus of said first conveyor beltand said second conveyor belt and said applicator pulley.
 141. The strawapplicator apparatus of claim 140 wherein said straws are individuallywrapped straws connected in a band.
 142. The straw applicator apparatusof claim 141 further comprising a knife for separating individuallywrapped straws from said band.
 143. The straw applicator apparatus ofclaim 142 further comprising an adhesive tape applicator for applying anadhesive tape to one side of said individually wrapped straws.
 144. Thestraw applicator apparatus of claim 143 wherein said first conveyorbelt, said second conveyor belt and said third conveyor belt operate ina timed relationship.
 145. The straw applicator apparatus of claim 144wherein said timed relationship is controlled by a sensor.
 146. Thestraw applicator apparatus of claim 144 wherein said third and fourthpulley include notches.
 147. The straw applicator apparatus of claim 144wherein said first conveyor belt, said second conveyor belt and saidthird conveyor belt include timing notches.
 148. The straw applicatorapparatus of claim 147 further comprising means for adjusting thedistance between said first conveyor belt and said second conveyor belt.149. The straw applicator apparatus of claim 148 further comprisingmeans for adjusting the distance between said knife and said notchedconveyor belt.
 150. The straw applicator apparatus of claim 148 whereinsaid first conveyor belt and said second conveyor belt are divided intotwo first conveyor belts and two second conveyor belts.
 151. A strawapplicator machine comprising: (a) a pair of abutting conveyorsincluding timing notches; (by a straw applicator conveyor belt extendingfrom a terminal end of said pair of abutting conveyors to a strawapplicator pulley, said straw applicator conveyor belt having notches onone side and vacuum ports on the other side communicating with saidnotches through said conveyor belt; and (c) a vacuum chamber forproviding a vacuum to a portion of said straw applicator conveyor. 152.The straw applicator machine of claim 151 further comprising timingmeans for operating said pair of abutting conveyors and said strawapplicator conveyor in a timed relationship.
 153. The straw applicatormachine of claim 152 further comprising a knife disposed intermediatethe ends of said pair of abutting conveyors.
 154. The straw applicatormachine of claim 153 further comprising an adhesive tape applicator forapplying an adhesive to one side of an individually wrapped straw. 155.The straw applicator machine of claim 154 further comprising atensioning and sequencing device for tensioning and sequencingindividually wrapped straws connected in a band. 156-163. Canceled. 194.A positive shut-off valve comprising: (a) a housing having an air inletat one end and a nozzle having a passage there through at the other end;(b) a diaphragm disposed intermediate said air inlet and said nozzle;(c) a chamber disposed intermediate said housing and said nozzlecommunicating with said passage on the side of said diaphragm oppositeto said air inlet; and (d) a fluid inlet communicating with saidchamber.
 195. The positive shut-off valve of claim 194 wherein saidnozzle is removable from said housing.
 196. The positive shut-off valveof claim 195 wherein said nozzle is composed of plastic.
 197. Thepositive shut-off valve of claim 196 wherein said nozzle includes a rimdisposed laterally adjacent to said diaphragm.
 198. The positiveshut-off valve of claim 197 wherein said diaphragm is activated by airpressure to open and close said passage to said chamber.
 199. Thepositive shut-off valve of claim 197 wherein said passage in said nozzleforms a plurality of outlets.
 200. The positive shut-off valve of claim199 wherein said plurality of outlets is four.
 201. The positiveshut-off valve of claim 199 wherein said plurality of outlets is nine.202. The positive shut-off valve of claim 197 wherein said diaphragmincludes a mating seat to said rim.
 203. The positive shut-off valve ofclaim 202 wherein said housing and said nozzle are of a cylindricalconfiguration.
 204. A straw applicator conveyor belt comprising: (a) anelastomeric belt having an inside surface and an outside surface ion.(b) a plurality of notches disposed on said outside surface; (c) a flatsmooth indented surface disposed on said inside surface; and (d) aplurality of passages connecting said flat smooth indented surface withsaid notches disposed on said outside surface.
 205. The straw applicatorbelt of clam 204 further comprising timing notches disposed at the edgesof said belt.
 206. The straw applicator belt of claim 205 wherein saidtiming notches are-disposed at the inside surface edges of said belt.207. The straw applicator belt of claim 205 wherein said flat smoothinside surface is disposed intermediate said timing notches.
 208. Thestraw applicator belt of claim 207 wherein said plurality of notchesextend past the sides of said elastomeric belt.